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Internee 



3600 Bar Code Label Printer 



P/N 062905-001 



Intermec® Corporation 
6001 36th Avenue West 
P.O. Box 4280 
Everett, WA 98203-9280 

U.S. technical and service support: 1-800-755-5505 

U.S. media supplies ordering information: 1-800-227-9947 

Canadian technical and service support: 1-800-688-7043 
Canadian media supplies ordering information: 1-800-268-6936 

Outside U.S. and Canada: Contact your local Intermec service supplier. 

The information contained herein is proprietary and is provided solely for the purpose of allowing 
customers to operate and/or service Intermec manufactured equipment and is not to be released, 
reproduced, or used for any other purpose without written permission of Intermec. 

Information and specifications in this manual are subject to change without notice. 

© 1995 by Intermec Corporation 
All Rights Reserved 

The word Intermec, the Intermec logo, Label Debut, and CrossBar are trademarks of Intermec 
Corporation. 

The name Centronics is wholly owned by GENICOM Corporation. 

IBM is a registered trademark of International Business Machines Corporation. 

Throughout this manual, trademarked names may be used. Rather than put a trademark (™) 
symbol in every occurrence of a trademarked name, we state that we are using the names only in an 
editorial fashion, and to the benefit of the trademark owner, with no intention of infringement. 

The software contained in the 3600 printer and the accompanying materials are copyrighted. 
Unathorized copying of the software, including software that has been modified, merged, or 
included with other software, or the written materials is expressly forbidden without the prior 
written consent of Intermec. All right, title, and interest in all copies of this software are and shall at 
all time remain the sole and exclusive property of Intermec. Customer may be held legally 
responsible for any copyright infringement that is caused or encouraged by its failure to abide by 
these terms. 



Contributors 



Technical Writer: 

Editor: 

Technical Illustrator: 

Technical Reviewers: 



Robert Shaw 

Craig Thompson 

George Wilson 

Cathy Aragon 
Pixie Austin 
Daniel Clark 
John Cramer 
Allen Crowe 
Stephen Eckert 
Pat Helton 
Laura McCluer 
Ed Millet 
Art Millican 
Matt Roberts 
Joe Wade 



/// 



Contents 




Contents 



Before You Begin xi 

Safety Summary xi 
Warnings and Cautions xii 
Purpose of This Manual xii 
Additional Information xv 




General Information 

Overview of the 3600 Printer 1-3 

3600 Features 1-4 

3600 Printer Specifications 1-4 

Dimensions (no options installed) 1-4 

Electrical Requirements 1-4 

Printing Methods 1-4 

Printing Speed 1-5 

Printhead Specifications 1-5 

Media Specifications 1-5 

Ribbon Specifications 1-5 

Environment 1-5 

Self-Strip Specifications 1-5 

Communications 1-6 

Fonts and Graphics 1-6 

Character Sets 1-6 

Memory 1-6 

Factory Default Settings 1-7 
3600 Printer Options 1-7 

Memory Expansion 1-7 

Twinax Interface 1-7 

Coax Interface 1-8 

Parallel Interface 1-8 

Network Connectivity 1-8 

Kanji/Katakana Character Support 1-8 

Batch Takeup 1-8 



3600 Printer Maintenance Manual 



Principal Functional Parts 1-9 

Basic Printer Setup and Operation 1-11 

Front Panel Operation 1-11 
Over-Temperature 1-11 
Media or System Faults 1-12 
Feed/Pause Pushbutton 1-12 

Checking the Printer Configuration 1-12 
DIP Switch Settings 1-13 

Connecting the Printer to a Computer 1-13 

Printing 1-14 

Using Label Debut 1-14 

Using Third-Party Software 1-14 

Using the Printer Command Set 1-15 



B 



Preventive Maintenance 

Preventive Maintenance Actions and Intervals 2-3 
Inspecting the Printer 2-4 

Cleaning the Printer 2-4 

Removing the Media Cover 2-5 
Cleaning the Printhead 2-6 
Cleaning the Rollers and Tear Bar 2-8 
Cleaning the Media Guides and Media Path 2-9 
Cleaning the Label and Ribbon Sensors 2-11 
Cleaning the Printer Covers 2-12 







Testing and Adjusting 



Testing the Printer 3-3 

Running Test and Service Mode at the Printer 3-4 

Setting DIP Switches 3-4 

Printing Test Labels 3-7 
Running Test and Service Mode From a Host Computer 3-11 
Testing Printer and Host Communications 3-12 



VI 



Contents 




H 



Adjusting the Printer 3-13 

Adjusting the Print Bias for Print Quality 3-14 

Adjusting the Print Intensity 3-15 

Adjusting the Printhead Adjustment Lever for Print Quality 3-16 

Adjusting the Label Mark Sensor 3-17 

Adjusting the Label Gap Sensor 3-19 

Adjusting the Label Taken Sensor 3-20 

Aligning the Printer 3-21 

Aligning the Rollers 3-22 
Aligning the Printhead 3-23 
Aligning the TTR Supply Hub 3-25 



Troubleshooting 

About Troubleshooting and Repair 4-3 

Troubleshooting Tips 4-3 
Where to Start 4-3 
Repair 4-3 

Troubleshooting Checklist 4-4 

Error Handling 4-5 

Syntax Errors 4-5 

Parameter Errors 4-5 

Image Overrun Errors 4-5 

Invalid Numeric Character Errors 4-6 

Insufficient Storage RAM Errors 4-6 

Error Codes 4-6 

Printer Operation Problems 4-9 

Print Quality Problems 4-10 

Communications Problems 4-12 

Environmental Problems 4-13 

Electrostatic Discharge (ESD) 4-13 

Electromagnetic and Radio Frequency Interference 4-14 

Ground Loops Between Equipment 4-14 

Inadequate Earth Ground 4-14 

AC Power Problems (Surges, Sags, Spikes, Noise, and Outages) 4-15 

Miscellaneous Problems 4-16 



VII 



3600 Printer Maintenance Manual 



m 




LiJ 




Remove and Replace Procedures 

Replacing Printer Components 5-3 

Replacing the Lithium Battery 5-4 

Replacing the Printhead 5-5 

Replacing the Bezel PCB 5-6 

Replacing the Main PCB 5-8 

Replacing the Kanji/Katakana Option PCB 5-9 

Replacing the Label Mark Sensor 5-10 

Replacing the Label Taken Sensor 5-12 

Replacing the Label Gap Sensor 5-13 

Replacing the TTR Drive Roller and Gear/Pulley 5-15 

Replacing the TTR Takeup Hub, Clutch/Pulley, and Belt 5-18 

Replacing the TTR Supply Hub and Adjusting Plate 5-20 

Replacing the Platen Roller and Gear 5-22 

Replacing the Liner Drive and Takeup Components 5-24 

Replacing the Stepper Motor 5-30 

Replacing the AC Plug/Input Filter 5-31 

Replacing the Power Switch/Circuit Breaker 5-32 

Replacing the Transformer 5-33 



PCB Drawings and Schematics 



Replacement Parts 



VIII 



Contents 





Appendix 

Functional Description of the 3600 Mechanics A-3 

Functional Description of the 3600 Electronics A-4 

Power Supply A-4 

+5V A-4 

+40V A-4 

+24V A-4 
Power Fail Detection A-5 
Battery A-5 

Battery Life Calculations A-5 
Reset A-5 
Motor Driver A-6 
Processor A-7 

Chip Selects A-7 

TPU A-7 

QSM A-8 

Interrupt Priority Levels A-8 

Crystal A-8 
Memory A-9 

Static RAM A-9 

EPROM A-9 

DRAM A-9 
Communications Interface A-10 
A/D Converter A-10 
DIP Switches A-10 
ASIC and I/O Option Interface A-10 

Address/Data Multiplexor A-10 

Chip Select Generation A-11 

I/O Option Connector A-11 
FIFO A-11 

Front Panel Interface A-11 
Debug Interface A-11 

Functional Description of the 3600 Software A-14 

Band Buffering and Font Caching A-14 
Image Band Buffering A-14 

Image Band Example A-15 
Font Caching A-18 

Print Energy Compensation A-18 

Digital Thermal Compensation A-18 
Global Compensation A-18 



IX 



Before You Begin 




Before You Begin 



This section describes the purpose and arrangement of this manual to you. It is 
intended to bring to your attention, important general safety concerns, specific 
warnings and cautions, and sources of additional information. 

Safety Summary 

Your safety is extremely important. Read and follow all of warnings and 
cautions in this book before handling and operating Intermec equipment. You 
can be seriously injured, and equipment and data can be damaged if you do 
not follow the safety warnings and cautions. 

Do Not Repair or Adjust Alone Do not repair or adjust energized equipment 
alone under any circumstances. Someone capable of providing first aid must 
always be present for your safety. 

First Aid Always obtain first aid or medical attention immediately after an 
injury. Never neglect an injury, no matter how slight it seems. 

Resuscitation Begin resuscitation immediately if someone is injured and stops 
breathing. Any delay could result in death or permanent injury. To work on or 
near high voltage, you should be familiar with approved industrial first aid 
methods. 

Energized Equipment Never work on energized equipment unless you are 
authorized by a responsible authority. Energized electrical equipment is 
dangerous. Electrical shock from energized equipment can cause death. If you 
must perform authorized emergency work on energized equipment, be sure 
that you comply strictly with approved safety regulations. 



XI 



3600 Printer Maintenance Manual 




Warnings and Cautions 

The warnings and cautions in this manual use the following format and 
address the issues described: 



A Warning 

A warning alerts you of an operating procedure, practice, condition, 
WARNING or statement that must be strictly observed to avoid death or 

serious injury to the persons working on the equipment. 



Caution 

A caution alerts you to an operating procedure, practice, condition, 
CAUTION or s t a t emen t th a t must be strictly observed to prevent equipment 

damage or destruction, or corruption or loss of data. 



Purpose of This Manual 

The purpose of this maintenance manual is to provide the information you 
need to clean, adjust, and repair the Intermec 3600 Bar Code Label Printer. 

Who Should Read This Manual? 

This manual is written for experienced electronic technicians trained by 
Intermec, who will service and, if necessary, repair the 3600 printer. Detailed 
operating instructions and specific related information is provided in the 3600 
Bar Code Label Printer User's Manual. 

This document is not intended to support user operations or persons untrained 
in troubleshooting and repair. You should have a working knowledge of 
electronics with an advanced understanding of PCs, DOS, data 
communications, and bar code applications. It is assumed that you are familiar 
with the installation, programming, and operation of the Intermec 3600 Bar 
Code Label Printer and all of its options, including a working knowledge of the 
Label Debut (or Label) software tool. 



XII 



Before You Begin 




How This Manual Is Organized 

You will find the following information in the referenced section: 



For information about: 

A basic description of the 3600 



Scheduled cleanings and checks 



Making sure the printer is operating 
correctly and providing quality results 



Problem solving 



Removing and replacing components 



Main PCB drawings and diagrams 



Spare parts 



Theory of operation 



Refer to: 

Chapter 1 - An illustrated overview of 
the 3600 printer; listing printer 
features, specifications, and options, 
identifying primary parts, and 
summarizing some setup and 
operating information. 

Chapter 2 - Actions, intervals, and 
illustrated preventive maintenance 
procedures. 

Chapter 3 - Procedures for running 
printer tests printing test labels, 
printing out the configuration settings, 
and for making printer adjustments 
and alignments. 

Chapter 4 - Information for 
identifying, duplicating, isolating, and 
eliminating conditions or failures in 
the printer environment or the printer 
components. 

Chapter 5 - Instructions for the 
removal and replacement of key 
components. 

Chapter 6 - Engineering drawing and 
schematic diagram of the main PCB. 

Chapter 7 - Two lists of the spare 
parts: one in ascending part number 
sequence and one alphabetically by 
description, keyed to exploded 
illustrations of the printer. Part 
numbers for tools and documentation 
are also provided. 

Appendix - functional descriptions of 
the 3600 mechanics, electronics, and 
firmware. 



XIII 



3600 Printer Maintenance Manual 



Terms and Conventions 

The following terms and conventions occur throughout this manual. A 
complete glossary of terms is provided in the 3600 Bar Code Label Printer User's 
Manual. 

Terms 

• "Backing" (or liner) refers to the silicon release portion of the media that 
carries the label. 

• "Host" refers to any computer that the printer is connected to. 

• "TTR" refers to the thermal transfer ribbon used when the printer is in 
thermal transfer rather than direct transfer mode. 

• "Media" is the stock on which the printer prints labels. Media can be made 
of plain paper, polyester, thermally reactive paper, or other materials with 
adhesive backing. 

Conventions 

The following conventions are used throughout this manual for operating 
procedures and descriptions of the printer. 

• Downloaded commands appear in the order that you enter them into the 
printer with the following conventions: 

Convention Description 

< > Angle brackets < > enclose mnemonic representations of 

ASCII control characters. For example, <ETX> represents 
the ASCII "End of Text" control character. 

{ } Braces {} enclose variable data. For example, {n} signifies a 

variable for which you can designate a constant value. 

I J Brackets around a word or letter represent a key on your 

keypad. For example, [Tab] represents the Tab key and [M] 
represents the letter M key. 

[ ]-[ ] When two keys are joined with a dash, press them 

simultaneously. For example, if you see the command 
[Ctrl]-[C], press the two keys at the same time. 

E3;F3 Enter all characters not enclosed in brackets by pressing an 

individual keypad key. For example, E3;F3; is entered as 
[E][3][;][F][3][;] with the E and the F in uppercase. 



XIV 



Before You Begin 




Additional Information 

The following documents may be of interest or help to you in servicing the 
3600 printer. 

3600 Bar Code Label Printer User's Manual (P/N 062732) 

Label Debut User's Manual (P/N 062982) 

Data Communications Reference Manual (P/N 044737) 

The Bar Code Book by Roger C. Palmer 



XV 




General Information 



General Information 




This chapter identifies basic features, options, and technical specifications of the 
3600 printer. It names principal functional parts and reviews basic printer setup and 
operation. 



Overview of the 3600 Printer 



The Intermec 3600 is a microprocessor-based thermal printer that prints 
standard bar code or 2D symbology, human-readable characters, graphics, 
lines, and borders on 3-inch (7.62 cm) to 6.6-inch (16.8 cm) wide continuous 
feed label stock. 

The 3600 prints directly to thermal label media or can print on regular label 
media with the use of a thermal transfer ribbon (TTR). 





The 3600 supports applications that need a wider print capability than the 
Intermec 3400 Bar Code Label Printer can provide. 



1-3 



3600 Printer Maintenance Manual 



3600 Features 

The 3600 printer's features are summarized in the following list: 
Print speed from 2 to 5 ips 

Programmable, nonvolatile printer configuration 
Bitmap font capabilities 
Outline/vector font support 
User selectable gap feature for fonts 

2D symbology support (Code One, PDF 417, and Maxicode) 
128k (standard), 512k (optional) storage memory 
Autoselection of Intermec protocols 
Printable control characters 
Image banding and memory management 
Dot-by-dot digital thermal compensation 
Self-strip or continuous print (with internal rewind) 
Media sensitivity numbering system 
Wide range of label media 
Label Debut™ label design software 



3600 Printer Specifications 



The specifications and performance parameters for the 3600 printer are 
itemized in this section. 



Dimensions (no options installed) 

Height 11 inches (27.9 cm) 

Width 12 inches (30.5 cm) 

Length 17 inches (43.2 cm) 

Weight 45 pounds (20.3 kg) 

Electrical Requirements 

Input Voltage 100, 115, or 230 VAC ± 10% 
Frequency 47 to 63 Hz 

Printing Methods 

Direct Thermal 

Thermal Transfer (thermal transfer ribbon (TTR) required) 



1-4 



General Information 




Printing Speed 

Maximum 5 ips (50.8 mm per second) 

Minimum 2 ips (127 mm per second) 

The print speed can be changed in 1 ips increments only: 2, 3, 4, or 5. 

Printhead Specifications 

Element size 0.00492 inch square (0.13 mm) 

Width 6.6 inches maximum print (168 mm) 

Resolution 203 dots per inch (8 dots per mm) 

# of Elements 1344 per printhead 

X dimensions 10 mil to 50 mil or 0.25 mm to 1.27 mm, 

5 mil (0.13 mm) in drag mode with specified media 

Media Specifications 

Roll 6,000 linear inches (152 m) 

Length 0.5 inch (13 mm) to 17 inches (432 mm) (stripped media) 

Width 3.0 inch (76 mm) to 6.7 inches (170 mm) 

Thickness 0.012 inches (0.3 mm) maximum 

Diameter 8.38 inch maximum diameter (213 mm) 

Ribbon Specifications 

Roll 6,000 linear inches (152 m) 

Widths 3.0 inches (76 mm) 

4.1 inches (104 mm) 
5.4 inches (137 mm) 
6.7 inches (170 mm) 

Diameter 2.25 inches maximum (57 mm) 

Environment 

Operating 50°F to 104°F (10°C to 40°C) 

Humidity 10% to 90% noncondensing 

Self -Strip Specifications 

The liner takeup hub can spool the backing of an entire 6,000-inch roll of 
media. 

Peel Release 10 to 50 grams 



1-5 



3600 Printer Maintenance Manual 



Communications 

Asynchronous RS-232C, RS-422, RS-485 interfaces 

Serial ASCII code 

Hardware (Ready/Busy) flow control 

XON/XOFF protocol 

Intermec Standard Block protocol 

Polling Mode D protocol 

Multi-Drop protocol 

Baud Rates: 1200, 2400, 4800, 9600, 19200 

Fonts and Graphics 

5x7, 7x9, 7x11, and 10x14 86XX compatible fonts 

2 bitmap OCR fonts 

3 bitmap fonts measured in point sizes 8, 12, and 20 
1 outline font 

12 monospaced bitmap fonts 
Kanji/Katakana bitmap font card (option) 
Kanji/Katakana bitmap and outline font card (option) 
UDF size of 4 inches (101.6 mm) maximum 
UDC size of 4 inches (101.6 mm) maximum 



Character Sets 

US ASCII Norwegian/Danish 


UK ASCII 


Swedish / Finnish 


German 


Italian 


French 


Spanish 


Swiss 




Memory 

Base 


512K of DRAM for imaging 
128K of SRAM for storage 


Optional 


512K of SRAM for storage 



1-6 



General Information 




Factory Default Settings 

The following is a list of the factory default settings for the 3600 printer: 



Configuration 


Default Setting 


Preamble Character 


Disabled 


Postamble Character 


Disabled 


Auto-Transmit 1 


Disabled 


Auto-Transmit 2 


Disabled 


Auto-Transmit 3 


Disabled 


Message Delay 


ms 


Power-Up Mode 


Advanced mode 


End-of -Print Skip Distance 


100 dots 


Top of Form 


20 dots 


Media Sensitivity 


420 


Number of Image Bands 


3 


Maximum Label Length 


1000 dots 


Printer Character Set 


US ASCII 


Label Retract 


Enabled 


Print Speed 


3 ips 


Label Stock Type 


Die-cut 


Intercharacter Delay 


ms 



3600 Printer Options 

The 3600 you are servicing can be equipped with one or more of the following 
options: 

Memory Expansion 

Storage memory for formats, pages, graphics, and fonts can be increased to 
512K of battery backed static RAM. This option provides an additional 512K of 
nonvolatile bulk storage to hold more formats, fonts, or bitmap graphics. It also 
increases the printer's image buffering capabilities. 

Twinax Interface 

Allows connection of the 3600 printer to IBM Twinax systems. The printer 
emulates an IBM 5256 Model 1 printer and can operate with an IBM System 
34/36/38 or AS/400 host computer. 



1-7 



3600 Printer Maintenance Manual 



Coax Interface 

Allows connection of the 3600 printer to IBM coax systems. The 3600 emulates 
an IBM 3287 printer by connecting the printer to IBM 3270 Type A coax cable 
computer systems operating in the VTAM (CICS/IMS/TSO) or 8100 (DPPX) 
environments. Connection can be made to an IBM 3174/76/99 system 
controller/multiplexer. 

Parallel Interface 

This option lets the user connect the 3600 to a PC through any Centronics™ 
parallel interface in addition to the standard serial interface. 

Network Connectivity 

Using the Parallel Interface option and an Ethernet or other network adapter, 
the 3600 can be connected to a network. 

Kanji/Katakana Character Support 

The 3600 has two Kanji/Katakana options: bitmap fonts only, or outline and 
bitmap fonts. Users shipping finished materials or work in process materials to 
Japan can meet Japanese label requirements for Kanji/Katakana (JIS 
Interleaved 2 of 5). 

Batch Takeup 

A larger diameter liner takeup hub permits printed labels to be spooled for 
later use without causing as much label curl as the smaller diameter hub. The 
maximum takeup outside diameter is 5 inches. 



1-8 



General Information 




Principal Functional Parts 



The following illustrations identify the common name and location of the major 
functional elements of the 3600 printer. 



Front Panel 



Media 
window 




Media access 
door 



Media 
cover 



Darkness adjust 
control 




DIP switches 

Optional I/O 

~ ~ board port 

Serial 
communications port 



AC power cord 
receptacle 



Power on/off 
switch 



Fanfold media 
access slot 



1-9 



3600 Printer Maintenance Manual 



Media post 



TTR supply hub 



TTR takeup hub 



TTR roller 



Tear bar I 




Platen 
roller 



Self-strip/ 
liner roller 



3E 9Uide 

Thermal 
printhead 



Upper media 
guide 

Lower media 



TTR/ribbon 




Media roll 

Media 
roll retainer 

Media 
post 



Lower media 
guide 



Media 
access door 



Printhead lift 
lever 



Self-strip/ 
liner roller Tear 
bar 



1-10 



General Information 




Basic Printer Setup and Operation 



Detailed operating instructions for the 3600 printer are contained in the user's 
manual. This section summarizes the following basic setup and operating 
information for you as a quick reference: 

• Front panel operations 

• Checking printer configuration 

• Connecting the printer to a computer 

• Printing 



Front Panel Operation 



The three light emitting diodes (LEDs) on the printer's front panel (Power, 
Alert, and Empty/Pause) indicate the conditions identified in the following 
illustration: 



Green LED- 

Orange LED~ 

YellowLED- 



-o 
-o 




Power 

Alert 

Empty/Pause 



Feed/Pause 



LED State 


Indication 


Off 


Power off 


On steady 


Power on 


Off 


Printing or idle 


On flashing 


Over-temperature 


On steady 


System fault 


Off 


Printing or idle 


On flashing 


Paused 


On steady 


Media fault 



Over-Temperature 

If the printhead reaches an over-temperature condition, the Alert LED on the 
printer flashes and the printer halts printing. Usually, you will not need to 
intervene. If you allow the printer enough time to cool down, it normally 
resumes operation on its own. 



1-11 



3600 Printer Maintenance Manual 



Media or System Faults 

If you are servicing a printer indicating a media or system fault, refer to 
Chapter 4, "Troubleshooting," for information about the problem. 



Feed/Pause Pushbutton 

Operating the Feed/Pause button produces the following actions, depending 
on what condition the printer is in: 



Printer Condition 

If the printer is idle: 



If the printer is printing: 



When the printer is first 
powered on: 



Operation/Function 

Pressing and releasing the Feed /Pause button 
causes the printer to feed out one label or a 
minimum specified amount of media. 

Pressing and holding the button down causes 
media to feed continuously until the button is 
released. 

Pressing the Feed /Pause button twice takes the 
printer offline. Press the button once more to 
bring the printer online. 

Pressing and releasing the Feed /Pause button 
causes the printer to pause. 

Subsequent pressing and releasing of the button 
allows the printer to resume printing. 

Pressing and holding the Feed /Pause button 
down until the printer stops printing cancels the 
current print job. 

Pressing and holding the Feed /Pause button 
down when turning printer power on places the 
printer in the Test and Service mode and causes 
the hardware configuration label to print. 



Checking the Printer Configuration 

The factory default settings for the 3600 printer are listed with the 3600 
specifications in this chapter. These parameters are set using a combination of 
DIP switch settings and downloadable printer commands, which are described 
in the user's manual. Remember, you can print out hardware and software 
configuration labels for statistics of the printer you are servicing. 



1-12 



General Information 




DIP Switch Settings 

The DIP switches on the rear panel of the printer control communications 
parameters, media type configuration, and test and service functions. To 
change settings, carefully position the plastic (breakable) switches to ON or 
OFF with a small straight-slot screwdriver. The printer is shipped from the 
factory in the standard configuration, with the 16 DIP switches set as shown in 
the following illustration. When changing switch settings, you must cycle the 
printer power from off to on for the changes to take affect. 



Factory 
Default Settings 




Connecting the Printer to a Computer 

To operate as intended, the 3600 must be interfaced with a computer (desktop 
or laptop PC, local area network, AS400 or similar mainframe) with its serial 
port configured for the communications protocol appropriate to the computer 
interface. It is assumed that the correct interface (point-to-point, non-switched 
modem, network, etc.) was achieved originally at installation and should have 
a history of correct operation. 

Refer to the 3600 User's Manual or contact an applications analyst for detailed 
information about the type of installation you are servicing. 



1-13 



3600 Printer Maintenance Manual 



Serial Port Settings 



Parameter 


Settings 


Baud Rate 


1200, 2400, 4800, 9600, 




19,200 


Parity 


Even, Odd, None 


Protocol 


Intermec, XON/XOFF, 




XON/XOFF with status 



Device 


AtoZ, 


Address 


0to5 


Test and 


Test Prints, Data Line 


Service 


Print, Cloning, Selective 




Transfer, Memory Reset 



Description 

The rate, in bits per second (bps) at 
which the host exchanges data with 
the printer. 

Checks each transmitted character for 
errors. 

The type of network used to connect 
the printer, the host, and the rest of 
the data collection system. Intermec 
protocol includes Standard, Polling 
Mode D, and Multi-Drop protocols. 

Unique address for each device 
connected using Multi-Drop protocol. 

Provides printer diagnostics to the 
host and prints test labels. 



Printing 

Regardless of your computer setup, you can use several methods to download 
information to print labels. This section describes different ways you can 
communicate with the printer. Refer to the 3600 User's Manual for detailed 
information. 

Note: Remember that these factors affect print quality: correct media, media sensitivity 
setting, -print speed, and correct bar code orientation. 



Using Label Debut 

If you are using a point-to-point (printer-to-PC) connection to communicate 
with the printer, the printer parameters can be easily set using the DOS-based 
software package Label Debut. The Label Debut prompting screens assist you 
in designing, printing, and editing labels. Refer to the Label Debut User's Manual 
for more detailed information. 

Using Third-Party Software 

Your customer may be using third-party software to create label formats and 
convert graphics into a UDC format that the 3600 printer can interpret. You can 
use the same software to set the printer parameters. 



1-14 




General Information 



Using the Printer Command Set 

You can also create labels by downloading formats (designs) and data created 
with the printer command set. The commands in the printer command set can 
perform any function or activate any feature of the 3600 printer. You can use 
the following methods to download commands: 

• Downloading printer commands using DOS 

• Using ASCII control characters or hexadecimal equivalents 

• Using readable protocol/command characters 

• Downloading printer commands with a PC communications program or 
host terminal 



Using a Novell network 



1-15 




Preventive Maintenance 



Preventive Maintenance 




This chapter identifies scheduled maintenance actions and provides illustrated 
procedures for cleaning the 3600 printer. 

Preventive Maintenance Actions and Intervals 



Printer Component 

Printer 
Printhead 



Preventive maintenance consists primarily of scheduled cleanings, but also 
occassional performance checks and, possibly, adjustments based on those 
checks. When you perform preventive maintenance, you should also conduct 
the tests and adjustments described in Chapter 3, "Testing and Adjusting," that 
will ensure the printer continues to deliver the highest quality output. You 
need to perform preventive maintenance procedures at the intervals identified 
to ensure a printer remains in proper working condition. 

The following table is a schedule of recommended printer cleaning and 
checking. Detailed cleaning procedures follow. Chapter 4, "Troubleshooting," 
contains instructions for performing various tests and adjustments. 

Maintenance Action and Interval 

Inspect the printer (and the rest of the data collection system) at every 
service visit. Your inspection should include the types of items listed in the 
following section. 

Inspect after every roll of media. Clean after every roll (or 6,000 inches) of 
media or more often if necessary. Inspect or test print quality every service 
visit. Make any necessary adjustments. 



Drive roller and tear bar 

Media path, edge, and 
guides 

TTR drive roller 

Liner drive roller 



Clean after every five rolls of media. Using hi-tack adhesive requires 
cleaning after every roll of media. If the customer uses tag stock or 
continuous media, you may want to clean after every five rolls of media, 
or more often if necessary. Harsh or dusty environments dictate the need 
to clean more frequently. Inspect or test the operation of these printer 
elements at every service visit. Make any necessary adjustments. 



Media supply post 
Label and ribbon sensors 
Pinch roller 



2-3 



3600 Printer Maintenance Manual 



Inspecting the Printer 



You should routinely inspect the printer and the rest of the data collection 
system. Your inspection needs to address the following and similar concerns: 

• Make sure the printer is properly grounded. 

• Make sure the printer's AC power source is within tolerance. 

• Make sure the printer is clean. 

• Make sure the printer is away from liquids. 

• Inspect the work environment for cleanliness and arrangement. Large 
electric motors, welders, and switching equipment can negatively affect 
printer performance. 

• Check the data collection network regularly for loose wires or poorly 
installed connections. Be sure to replace corroded wires. 



Cleaning the Printer 



Use these procedures to access the printer parts and clean them. Heed the 
warnings and cautions to prevent harm to yourself or damage to the printer. 
You will need the following items to clean the printer correctly: 

Isopropyl alcohol 

Cotton swabs 

Clean lint-free cloth 

Soft bristle brush 

Vacuum cleaner 

Soapy water/mild detergent 



A 

WARNING 



Warning 

Energized electrical equipment is dangerous. Switch off the printer 
power and remove the power cord before cleaning any part of the 
printer. Failure to comply can result in injury or death. 



2-4 



Preventive Maintenance 




Removing the Media Cover 

Most of the cleaning procedures require that you remove the media cover. 

To remove the media cover 

1 . Place your fingers in the space at the lower center edge of the media cover 
and pull the bottom of the cover away from the base of the printer. 

2. Grasp the front of the media cover and lift the front of the cover upward. 




Media 
cover 



Media cover 
release 
(between the two 
notches) 



3. Lift the media cover away from the printer. 



2-5 



3600 Printer Maintenance Manual 



Cleaning the Printhead 

Since the printhead must maintain close contact with the media to provide 
good print quality, cleaning media debris from the printhead is very important. 
Clean the printhead after every roll (or 6,000 inches) of media or whenever 
necessary. 




CAUTION 



Caution 

Do not use sharp objects such as knives or screwdrivers to scrape 
the printhead clean. Cleaning with sharp objects will damage the 
printhead. Clean with only a cotton swab, or a clean, lint-free cloth 
or tissue moistened with isopropyl alcohol. 



To clean the printhead 

1 . Remove the media cover. 

2. Raise the printhead by rotating the head lift lever clockwise until the 
printhead releases. 



TTR/ 
ribbon 




Media roll 



Printhead 
lift lever 



2-6 



Preventive Maintenance 




3. Remove the media from the paper path and the ribbon (if installed) from 
the TTR supply and takeup hubs. 

4. Use a cotton swab moistened with alcohol to remove any dirt, adhesive, or 
debris from the print surface on the bottom of the printhead. 




Thermal 
printhead 



3600M.012 



5. Wait 5 to 10 seconds for the print surface to dry. Reload the media (and 
ribbon if used). 

6. Engage the printhead by rotating the head lift lever counterclockwise until 
it locks in place. 

7. If you are finished cleaning, install the media cover. 



2-7 



3600 Printer Maintenance Manual 



Cleaning the Rollers and Tear Bar 

Cleaning the platen roller and the tear bar preserves print quality by ensuring 
close contact between the media and the printhead. The TTR roller, liner roller, 
and media roller are cleaned in the same fashion to minimize general debris 
and to maximize their efficiency. 

To clean the rollers and tear bar 

1 . Remove the media cover. 

2. Raise the printhead by rotating the head lift lever clockwise until the 
printhead releases. 

3. Remove the media from the paper path and the ribbon (if installed) from 
the TTR hubs. 

4. Clean the rollers with a lint-free cloth moistened in isopropyl alcohol. Wipe 
the cloth over the rollers, rotating each roller so that you clean all of it. 



Media roll 
roller 



TTR 
roller 




\+4fr\ Platen 
roller 
Tear \ 

bar Lmer 
roller 



5. Clean both sides of the tear bar with a lint-free cloth moistened in isopropyl 
alcohol. Remove all traces of dust, paper, and adhesive. 

6. Reload the media (and ribbon if used) and then engage the printhead by 
turning the head lift lever counterclockwise until the printhead locks. 

7. If you are finished cleaning, install the media cover. 



2-8 



Preventive Maintenance 




Cleaning the Media Guides and Media Path 

Clean the media guides and media path regularly to keep debris off the media 
surface and printhead where irregularities can spoil print quality or damage 
the printhead. Cleaning the guides also helps prevent media skewing or 
improper tracking as it travels through the paper path, which can result in 
print problems. Always clean the media guides immediately after any label jam 
in the printer. 

Media debris may accumulate around the printer mechanism and along the 
media path during normal operation of the printer. Clean debris away using a 
soft bristle brush or vacuum cleaner. Remove all traces of dust, paper, and 
adhesive. Clean the flat surfaces of the media path (including the edge guide) 
with a lint-free cloth and isopropyl alcohol. Also remove all traces of dust, 
paper, and adhesive from the pinch rollers on the media access door. 

To clean the media guides and media path 

1 . Remove the media cover. 

2. Remove the media from the paper path and the ribbon (if installed) from 
the TTR hubs. 

3. Pull down and hold the spring-loaded lower media guide to open up the 
media path. 

4. Clean the lower media guide with a lint-free cloth moistened in isopropyl 
alcohol. 




Upper media 
guide 



Lower media 
guide 



2-9 



3600 Printer Maintenance Manual 



5. Use a lint-free cloth moistened with isopropyl alcohol to clean the upper 
media guide. Be sure to remove all traces of debris. 

6. Reload the media (and ribbon if used). 

7. If you are finished cleaning, install the media cover. 

To clean the pinch rollers 

1. Open the media access door. 

2. Use a cotton swab moistened with isopropyl alcohol to clean the pinch 
rollers. Rotate the rollers to get any debris out of all of the grooves. 




Pinch 
Roller 

Media 

access 

door 



3600M.015 



3. If you are finished cleaning, install the media cover. 



2-10 



Preventive Maintenance 




Cleaning the Label and Ribbon Sensors 

There are three label sensors and a ribbon sensor on the 3600 printer that 
require cleaning: the label taken sensor, the label mark sensor, the label gap 
sensor, and the ribbon motion sensor. 

To clean the sensors 

1 . Remove the media cover. 

2. Raise the printhead by rotating the head lift lever clockwise until the 
printhead releases. 

3. Remove the media from the paper path and the ribbon (if installed) from 
the TTR hubs. 

4. Clean the label taken sensor and the label mark sensor with a cotton swab 
moistened with isopropyl alcohol. 



Encoder 
decal 




3600M.016 



2-11 



3600 Printer Maintenance Manual 



5. Pull down on the lower media guide to expose the label gap sensor. Using 
a soft bristle brush, remove all debris and dust from the label gap sensor. 

6. Clean the label gap sensor with a cotton swab and alcohol. 

7. Remove the electronics cover. 

8. Very carefully clean the small ribbon motion optical sensor on the main 
PCB and the black and white encoder decal on the TTR supply 
clutch/ encoder assembly with a cotton swab moistened with alcohol. 

9. Install the electronics cover. 

10. Reload the media (and ribbon if used). 

11. Engage the printhead by rotating the head lift lever counterclockwise until 
it locks in place. 

12. If you are finished cleaning, install the media cover. 

Cleaning the Printer Covers 

Clean the 3600 printer covers with a general purpose cleaner (soapy 
water/mild detergent). Do not use abrasive cleansers or solvents. Be sure to 
clean the transparent panel on the media cover so that you can see the media 
supply inside the printer when the cover is closed. 



2-12 




Testing and Adjusting 



Testing and Adjusting 




This chapter contains procedures for testing the printer's performance as a quality 
check during preventive maintenance, as a functional check when troubleshooting, 
and as part of the repair process after replacing a printer component. This chapter 
also contains procedures for making adjustments and alignments that ensure the 
printer is operating normally. 



Testing the Printer 



If you are on site for preventive maintenance or are following up a corrective 
action and the printer is working, start conducting quality checks from the Test 
and Service mode. If you are on site for corrective maintenance, determine if 
the problem lies with setup and process or the printer itself. Use the Test and 
Service mode to determine if the printer can print. If it can, perform the 
communications test. 

The quality and efficiency of producing labels reveals if a printer is operating 
correctly. In addition to analyzing labels to evaluate printer performance, the 
3600 printer Test and Service mode allows you to conduct printer tests that 
include printing test labels (illustrated in this section) with a fixed look so you 
can compare them to an expected standard. The test labels can be used for 
checking printhead alignment, printhead bias, dots out of specification, label 
tracking, and ribbon wrinkling. Test and Service mode functions can be run at 
the printer or from a host terminal through the use of commands. 

If you find a printer lacking in performance after running your tests, check and 
make the adjustments and alignments necessary to return the printer to normal 
service. If you cannot get a printer working properly with an adjustment or 
alignment, troubleshoot for a component failure. 

Note: Making the alignments out of order can introduce, not solve -printing -problems. 
Review the section about printer alignments before making any changes. 



3-3 



3600 Printer Maintenance Manual 



Running Test and Service Mode at the Printer 

Note: When the printer is placed in Test and Service mode, it prints out a hardware 
configuration label, regardless of its initial DIP switch settings, and remains in Test 
and Service mode until the power is switched off and the DIP switches are reset. 
Momentarily pressing the Feed/Pause button during a test will cause the test to halt. 
Holding the Feed/Pause button down will start a new run of whichever test you select. 



To enter Test and Service mode and select test functions at the printer 

1 . Switch off the printer power. 

2. Set the DIP switches to select the function that you want to run. 

3. Press down and hold the Feed/Pause button while powering on the 
printer. The printer prints out a hardware configuration label. 

4. Hold the Feed/Pause button down for 1 second. The test begins 
immediately. 

5. If you wish to perform another function, repeat Steps 1 through 4. The 
function currently being executed is terminated and the new function 
begins. 

To exit Test and Service mode 

1 . Switch off the printer power. 

2. Return all DIP switches to their original settings. 

3. Switch on the printer power. 



Setting DIP Switches 

Use the information provided in the following tables and examples to set the 
DIP switches for the Test and Service mode function that you wish to perform. 
The "0"s indicate that the switch is in the OFF position and the "l"s indicate 
that the switch is in the ON position. 



3-4 



Testing and Adjusting 




Test and Service Switch Settings 



Top Ban k 



= OFF 0FF 


P 
















Hi 
















1 =ON 


flf 


'A' A 1 A 


7J 


A 


j\ 


A 


j\ 


5aaa 


yj 


A 


J I 


TESTS ON 


1 


2 3 


4 


5 6 


7 


8 


1 


2 3 4 5 


6 7 8 


Test Prints 




















Configurations 




















Hardware 


























A 


Software 














1 











A 


Test Labels 




















Print Quality 








1 

















A 


Pitch 








1 





1 











A 


Page 




















Single Page 











1 








B 


B B B B 


A 


All Pages 








1 


1 


1 





1 


1111 


A 


Format 




















Single Format 








1 


1 








B 


B B B B 


A 


All Formats 








1 


1 


1 





1 


1111 


A 


UDC 




















Single UDC 











1 








B 


B B B B 


B B A 


All UDCs 











1 


1 





1 


1111 


1 1 A 


Font 




















Single Font 








1 


1 








B 


B B B B 


BOO 


All Fonts 








1 


1 


1 





1 


1111 


1 


Data Line Print 


1 


























Cloning 




Receiver 





1 























Sender 





1 


1 




















Selective Transfer 




















Receiver 


1 


1 























Send Pages 




















Single Page 




1 


1 





C 


C 


c 


C C D D 


D D D 


All Pages 




1 


1 





1 


1 


1 


1111 


1 1 1 


Send Format 




















Single Format 




1 





1 











D D 


D D D 


All Formats 




1 





1 


1 


1 


1 


1111 


1 1 1 


Send UDC 




















Single UDC 




1 


1 


1 


C 


C 


c 


C C C C 


COO 


All UDCs 




1 


1 


1 


1 


1 


1 


1111 


1 


Send Font 




















Single Font 




1 





1 


C 


C 


c 


C C D D 


D D 


All Fonts 




1 





1 


1 


1 


1 


1111 


1 1 1 


Send Configuration 




1 


1 


1 

















Send Tables 




1 





1 1 

















Send All 




1 


1 


1 1 

















Memory Reset 




















Page/Format 





1 























UDC/Font 





1 


1 




















Configuration 





1 





1 

















Tables 





1 


1 




















All 





1 


1 


1 1 

















A: OFF = Batch of 1. ON = Batch of 100 
















B: Page/Format/UDC/Font number. 


Least significant bit first 








C: Source Page/Format/UDC/Font number. Least significant bit first. 






D: Destination Page/Format/UDC/Font number 


Least sig 


nificant bit first. 





3-5 



3600 Printer Maintenance Manual 



Test and Service Configuration Settings 



Top Bank 



Bottom Bank 



= OFF 

1 =ON 



OFF \ 



ON 





Label Rest Point 

Adjust Forward 
Adjust Backward 

86XX Emulation 

Advanced Mode 
10 Mil 
15 Mil 

X Forms Adjust 

Adjust Forward 
Adjust Backward 

Y Forms Adjust 



1 1 



1 O 1 



1111 



1110 



o 




N 


N 


N 


N N 


1 




N 


N 


N 


N N 


o 













1 













1 


1 










1 

















N 


N 


N 


N N 




1 


N 


N 


N 


N N 



N: Number. Least significant bit first. 



N N N N N 



Dot Increment Switch Settings 



Bottom Bank 



= OFF 

1 =0N 



OFF 



ON 




# of dot increments 

1 

2 

3 

4 

5 

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

17 

18 

19 

20 

21 

22 

23 

24 

25 

26 

27 

28 

29 

30 



3600M.022 



3-6 



Testing and Adjusting 




Printing Test Labels 

The test labels can be used for checking printhead alignment, printhead bias, 
dots out of specification, label tracking, and ribbon wrinkling. The examples 
show the DIP switch settings that select the illustrated label. 

Hardware Configuration 

The hardware configuration label is the first label printed when you enter Test 
and Service mode. This label serves as a configuration reference as well as an 
alphanumeric and alignment print test. This label contains the following 
information and uses: 

• Printer memory including both storage and image RAM. 

• Printer mileage including inches processed and inches burned. 

• Printhead settings including width, dot size, and burn pot setting. 

• Firmware checksum, program, and version number. 

• Vertical lines for evaluating printhead alignment. 

To achieve the highest quality label, print the hardware configuration label at a 
speed of 3 ips (inches per second). 



3600 Hardware Configuration 



Memory Installed 




Storage RAM 


128 kilobytes 


Image RAM 


382 kilobytes 


Flash RAM 


none 


Mileage 




Inches Processed 


540 


Inches Burned 


204 


Labels Cut 





Printhead 




Width 


1344 dots 


Dot Size 


5.0 mil 


Burn Pot Setting 


213 


Hardware Options 




I/O Option 


none 


Internal Option 


none 


External Option 


Self Strip 


Firmware Checksum 




ROMO (U9) 


FAC3 


ROM1 (U8) 


OC3E 


Program 


062198 


Version 


1.1 



ON 


1 2 3 4 5 6 7 8 


ON 


1 2 3 4 5 6 7 8 



OFF 



OFF 



3-7 



3600 Printer Maintenance Manual 



Software Configuration 

This three-label set lists current configuration parameters that are set from the 
host computer. It also lists defined pages, formats, graphics, fonts, and 
installed options. This label serves as a configuration reference as well as an 
alphanumeric and multiple label alignment and print test. 







\ 




r \ 




r 


Program Version : 


1.1 






PRINT SPEED - 3.0 IPS RIBBON SAVE - Disabled 




BAUD RATE -9600 


Pages Defined : 









IMAGE BANDS -3 SELF STRIP - Disabled 




DATA BITS - 7 


Formats Defined : 


0, 19 






MAX LABEL LENGTH - 4 inches CUTTER - Disabled 




MESSAGE LENGTH -255 


Fonts Defined : 


0, 1,2, 7,20 21,22,23,24, 
25,30,31,32,33,34,35,36 
37, 38, 39, 40, 41 






LABEL STOCK - Infer- label gap DARK ADJUST - 
MEDIA TYPE - Direct Thermal X FORMS ADUST - 




PARITY - Even 

STOP BITS - 1 


Graphics Defined 


none 


/ 




MEDIA LENGTH - inches Y FORMS ADJUST - 10 
CHARACTER SET - US ASCII LABEL REST POINT - 
TRANSLATION - Disabled SENSITIVITY • 420 
EMULATION - Disabled 
LABEL RETRACT - Enabled 




PROTOCOL - Xon/Xoff No Status 
DEVICE ADDRESS -A 
INTERNAL OPTIONS -none 
EXTERNAL OPTIONS - Self Strip 



ON 


12 3 4 5 6 7 8 


ON 


12 3 4 5 6 7 8 



Print Quality 

This label contains bar codes and human readable fields that you can use to 
determine whether the printer you are testing is attaining the best print quality 
possible. If you notice problems with the print quality, check and perform the 
adjustment and alignment procedures provided in this chapter to achieve 
optimum printer performance. 



o 






o 




= O 












- 1 m 


CO 










CO 


^=^ 


-^ 
















^^ 


m 






























_. JU 





^<: 


^^_ 






SO 








So 






o 









<_> 


^^^ 


o 








£B 













O 




^ 



en O 



ON 


-EL^ffiU 

~E_q^ 

"ECtf 

-E_q^ 
*E_q^ 


ON 


12 3 4 5 6 7 8 



OFF 



OFF 



3-8 



Testing and Adjusting 




Format 

This label, which can be a test of a single format or can provide a two-label 
sample of all the formats, has bar codes and human-readable fields that you 
can use to determine whether the printer you are testing is attaining the best 
print quality possible using a particular format. 





CD 3600 TEST LABEL 

^= 1 3600 TEST LABEL 

3600 TEST LABEL 

3600 TEST 

mi mi inn inn iiiiiiiiiiiiiiiiiiiiii mi 

DT / TTR PRINT QUALITY SAMPLE 



ON 


12 3 4 5 6 7 6 


ON 


1 2 3 4 5 6 7 8 



Pitch 

This label is a gray scale printout of every third dot. The test label should 
present a regular pattern with dots that line up diagonally when held at an 
angle. Look for irregularities that may signal a problem with the platen roller 
or the media path. If the printhead is uneven or the print path is skewed, it will 
be reflected in this label. Use this label to determine whether the printhead is 
printing evenly, but use the actual customer format to pass /fail the printhead. 



ON 


12 3 4 5 6 7 8 


ON 


1 2 3 4 5 6 7 8 



3-9 



3600 Printer Maintenance Manual 



Font 



This is a multiple-label test of the available fonts. You can test a single font 
(Font 20 shown) or all of the fonts. An all-font test will use a lot of media. It is 
better that you test one font at a time to make your determinations. 



f 






/ 


o 

CM 


4 


8 12 


16 2 


£ 1 

o 

LL 

2 


5 
6 


9 13 

10 14 


17 2 
18 2\ 


3 


7 


11 15 


19 23 \ 


V 






/ 



/1 24 128 132 136 140 
1 125 129 133 137 141 
26 130 134 138 142 



192 196 200 204 

A A E i 

193 197 201 205 
\194 198 202 206 



,A Q E I 

131 135 139 143 14\ }5 199 203 207 





J K1P 




»1^0J 




-fcCjU 


ON 


■di] 




-OT 




"M 


^^ 




-bciu 




"^^ 


ON 


*UP 

-a^ 








-^BU 



These labels test the ability to download and correctly print single or multiple 
pages (a group of labels always printed together) of label data from a host. The 
data can be yours or the customer's, but you should include a test of the 
customer's labels to determine whether the printer you are testing is attaining 
the best print quality possible with the customer's data. 

UDC 

This label tests the ability to download and correctly print single or multiple 
user-defined characters (bitmap graphic) from a host. The data can be yours or 
the customer's, but you should include a test of the customer's labels to 
determine whether the printer you are testing is attaining the best print quality 
possible with the customer's data. 



3-10 



Testing and Adjusting 




Running Test and Service Mode From a Host Computer 

When conducting Test and Service mode functions from a computer, hardware 
diagnostic information is uploaded to the host from the printer. 

The following table describes the commands you would issue from a host 
terminal to run the Test and Service mode. To select Test and Service mode 
from Print mode, send <ESC>T from the host terminal. 

Note: All commands in Test and Service mode end with the command terminator (;), 
except the last command in a message. 



Test and Service Mode Command Descriptions 



Command Code 

A 
B 

C 

D 



K 



M 



Q 



Test 

Transmit Ambient 
Temperature* 

Printhead Resistance 
Test* 

Print Pitch Label 

Reset Printer 
Configuration 

Transmit 

Transmissive Sensor 
Value 

Dark Adjust* 

Transmit Paper Path 
Open Sensor Value* 

Transmit Reflective 
Sensor Value 

Transmit Printhead 
Temperature Sensor 
Value 

Print Quality Label 



R Exit Test and Service 

* The printer ignores this command. 



Description 

Transmits the ambient temperature sensor output back to 
the host. The value ranges from 00 to FF. 

Causes the printer to begin the printhead resistance test. The 
printer will respond with the ASCII character string "pass" 
or "fail." 

Causes the printer to print the pitch label. 

Sets the printer configuration to the factory defaults. 

Transmits the label gap output back to the host. Values 
ranges from 00 to FF. 

This command changes the darkness of the print on your 
labels. It is for fine-tuning only. 

Transmits the Paper Path Open switch value back to the 
host. A value of indicates the paper path is open and a 
value of 1 means it is closed. 

Transmits the label mark reflective sensor output back to the 
host. The values range from 00 to FF. 

Transmits the Printhead Temperature Sensor output back to 
the host. Values range from 00 to FF. 

Causes the printer to print out the print quality program 
and model number label. 

Causes the printer to exit Test and Service mode. 



3-1 1 



3600 Printer Maintenance Manual 



Test and Service Mode Command Descriptions (continued) 
Command Code Test Description 

S Transmit Printhead Transmits the average, maximum, or minimum printhead 

Resistance Values* dot resistance value back to the host. Each value is a 

numeric data string separated by a comma. 

T Transmit Label Transmits the label taken sensor output back to the host. 

Taken Sensor Value Values can range from 00 to FF. 

U Transmit 40V Supply Transmits the 12V supply output back to the host. The 

Value* values range from 00 to FF. 

V Transmit 24V Supply Transmits the 24V supply output back to the host. Values 

Value* can range from 00 to FF. 

* The printer ignores this command. 



Testing Printer and Host Communications 

This is a simple test of host-to-printer communications. If this test fails, there 
may be a problem with the printer serial port receiver circuitry or the setup. 

To test host-to-printer communications 

1 . Switch the printer power off. Return the DIP switch settings to the standard 
configuration if they have been changed. 

2. Press and hold the Feed/Pause button while powering on the printer. The 
printer presents the hardware configuration test label. 

3. Release the Feed/Pause button after the hardware configuration label is 
printed. You are now in data line print mode within the Test and Service 
mode. 

4. Send down some characters from the host. At this point the printer does 
not attempt to interpret any printer commands, but simply prints each 
character and its hexadecimal equivalent as it is received. If you are using a 
PC running DOS, send down the following strings of commands from the 
DOS prompt: 

Note: A Zis[Ctrl][Z]. 

\MODE COM1 : 96,E,7,1,N [Enter] 
(to configure the serial port) 

\COPY CON COM1 : [Enter] 

(tells the PC to copy the following text to the COM1 port) 

ABCDEF A Z [Enter] 

(these characters are sent to the printer) 



3-12 



Testing and Adjusting 




5. A good test will result in the following printout : 

R B C D E F 
41 42 43 44 4546 



6. To enter normal print mode again, switch the printer power off and then on 
again. 

If this test does not work, recheck after you make sure that the DIP switches 
are set to the default configuration and that the printer cable is securely 
plugged into COM1 of your PC. 

Note: If you are using a different platform to communicate with your -printer, refer to 
your host computer user's manual and the 3600 Bar Code Printer User's Manual 
for more detailed information about downloading commands. 



Adjusting the Printer 



The following procedures provide instructions for adjusting the print bias, the 
print intensity (darkness), the label mark sensor, the label gap sensor, the label 
taken sensor, and the printhead fine adjustment lever on the 3600 printer. 

A Warning 
Always disconnect the power cord before removing the electronics 
WARNING cover unless a procedure requires the unit to be energized. Failure to 
disconnect the power cord may result in injury or death due to 
electric shock. 



Caution 

The printhead and integrated circuits on printer circuit boards in 
CAUTION th* s equipment are sensitive to damage by electrostatic discharge 
(ESD). Prevent ESD by always wearing skin contact ground straps 
firmly attached to the equipment metal base assembly when 
working inside of the equipment housing. Failure to comply can 
result in damage to components or the printhead. 



3-13 




3600 Printer Maintenance Manual 



Adjusting the Print Bias for Print Quality 

Adjust the bias with a straight-slot screwdriver if the printhead is not making 
even contact with the media. Using different width media, especially narrow 
media, can result in uneven contact or a spot where there is no media between 
the printhead and the platen roller. Extra wear and damage can occur if narrow 
media is used for extended periods with incorrect bias. 

To adjust the bias adjust screw 

1. Remove the media cover and locate the bias adjust screw. 



Printhead bias 
adjust screw 




3600M.030 



2. Turn the bias adjust screw counterclockwise to compensate for light print 
on the right side of the label; turn the bias adjust screw clockwise to 
compensate for light print on the left side. 



^> 



If printing is light on 
the right side of label, 
turn the bias adjust screw 
counterclockwise. 




m 



fl 



^ 



If printing is light on 
the left side of label, 
turn the bias adjust screw 
clockwise. 




3. Install the media cover. 



3-14 



Testing and Adjusting 




Adjusting the Print Intensity 

Note: Before you adjust print intensity, verify the sensitivity rating for the media 
matches the rating set in the printer. 

Use the darkness adjust control in combination with the darkness adjust 
command <SI>d to fine-tune the intensity of print on your customer's labels. 
The fine adjustments compensate for variations in the media ("lot to lot"), the 
printhead, or the printer. Set the darkness adjust control with a small straight- 
slot screwdriver after entering the proper sensitivity number. 

To adjust the print darkness control 

1. Locate the darkness adjust control on the back of the printer. Make 
adjustments with a small straight-slot screwdriver. 



Turn the darkness 
adjust control clockwise 
1 | for darker density. Darkness 

adjust control 




Turn the darkness adjust 
control counterclockwise 
for lighter density. 



2. Increase the darkness by turning the darkness adjust control clockwise or 
decrease the darkness by turning the control counterclockwise. Run a test 
print to evaluate the print quality. 



3-15 



3600 Printer Maintenance Manual 



Adjusting the Printhead Adjustment Lever for Print Quality 

The printhead adjustment lever is located at the end of the printhead pivot 
bracket. It allows fine-tuning of the printhead fore/ aft position. The printhead 
adjustment lever provides three stops forward movement of the printhead and 
three stops backward movement from center position in 0.006-inch increments. 

To achieve the best print quality, raise the printhead with the printhead lift 
lever and position the printhead adjustment lever as shown in the illustration: 
from the rear, adjust clockwise /left to move the printhead forward, or adjust 
counterclockwise/right to move the printhead backward. 




Printhead 

adjustment 

lever 



3-16 



Testing and Adjusting 




Adjusting the Label Mark Sensor 

The mark sensor detects the mark on the back of continuous media stock. The 
output is then used to determine the start of print point. This sensor is located 
under the label pathway across from the platen roller. Two adjustments affect 
the performance of this sensor, its physical position and sensitivity. To perform 
this procedure, you need the following tools: 

• Digital multimeter 

• #2 Phillips screwdriver 

• Small straight-slot screwdriver 

To position the label mark sensor 

1 . Remove the media cover. 

2. Use your finger to reach underneath the lower guide. 



Platen 
roller 

Locate the label mark sensor 
behind the platen roller near 
the inboard edge of the printer. 
Use your index finger to adjust ; 
the label mark sensor. 



Inboard edge 
of printer. 
The platen roller 
is not shown 
for clarity only 




3-17 



3600 Printer Maintenance Manual 



Slide the mark sensor into a position that centers it over the label mark as 
the media passes by. It is adjustable from the inboard edge of the extrusion 
to one half of the paper path width toward the outboard edge. 



To adjust the label mark sensor potentiometer sensitivity 

1 . Remove the electronics cover 

2. Switch on the printer power. 

3. Enable the printer for mark sensing using the <SI>T{2} command. 

4. Connect the positive lead of a digital voltmeter to TP18 (MARK) and the 



negative end to TP14 (GND) on the main PCB. 



R191 




3600M.035 



5. Place the white portion of a label under the mark sensor. 

6. Adjust R191 on the main PCB so the voltage at TP18 is IV ± 0.2V. 

7. Place the black mark portion of the label under the mark sensor. 

8. The voltage at TP18 should now be greater than 2.5V. 

9. Install the printer electronics cover and the media cover. 
10. Check the printer for proper operation. 



3-18 



Testing and Adjusting 




Adjusting the Label Gap Sensor 

The label gap sensor output enables the software to determine the leading edge 
of a label by detecting the label gap. The label gap is the space between labels 
on the backing material. This reading enables the printer to properly position 
the start of print point. To perform this procedure, you need the following 
tools: 

• Digital multimeter 

• #2 Phillips screwdriver 

• Small straight-slot screwdriver 

To adjust the label gap sensor potentiometer 

1 . Remove the media cover and the electronics cover. 

2. Connect the positive lead of a multimeter to TP15 (GAP) and the negative 
lead to TP14 (GND) on the main PCB. 




R124 



3600M.036 



3. Switch on the printer power. 

4. Insert the label backing only in the label gap sensor. Adjust R124 on the 
main PCB so that the voltage at TP15 (GAP) is IV ± 0.2V. 

5. Insert both the label and the label backing in the sensor. Verify that the 
voltage at TP15 (GAP) is greater than 3V. 

6. Install the printer electronics cover and the media cover. 

7. Check the printer for proper operation. 



3-19 



3600 Printer Maintenance Manual 



Adjusting the Label Taken Sensor 

The label taken sensor output enables the software to determine that a label has 
been taken by detecting the label's presence. To perform this procedure, you 
need the following tools: 

• Digital multimeter 

• #2 Phillips screwdriver 

• Small straight-slot screwdriver 

To adjust the label taken sensor 

1 . Remove the media cover and the electronics cover. 

2. Connect the positive lead of a multimeter to TP19 (TAKEN) and the 
negative lead to TP14 (GND) on the main PCB. 



R190 



DC 

. iioorflro 




IJ.III.r '0DD000D0I 



I^Lli 



D Q ! 




30| JLjf pl * 00 

ooc oool " Ui tl oo 
oo 



Ooo 
" 



■ice of 
DD □ 
DD □ 



3600M.037 



3. Switch on the printer power. 

4. Feed one label out of the printer so that it rests under the label taken sensor 
in a correct orientation. 

5. Adjust R190 on the main PCB until the voltage at TP19 is 1.2V + 0.2V. 

6. Remove the label from under the label taken sensor. 

7. The multimeter reading at TP19 should now read above 4.5V. 

8. Install the printer electronics cover and the media cover. 

9. Check the printer for proper operation. 



3-20 



Testing and Adjusting 




Aligning the Printer 



The following procedures provide instructions for aligning the rollers, aligning 
the printhead, and aligning the ribbon supply hub on the 3600 printer. 

Note: These alignments should be made in the sequence given. Performing them out of 
order can introduce and not solve -printing -problems. 



A Warning 
Always disconnect the power cord before removing the electronics 
WARNING cover unless a procedure requires the unit be energized. Failure to 
disconnect the power cord may result in injury or death due to 
electric shock. 



Caution 

Integrated circuits on printer circuit boards in this equipment are 
CAUTION sensitive to damage by electrostatic discharge (ESD). Prevent ESD 
by always wearing skin contact ground straps firmly attached to 
the equipment metal base assembly when working inside of the 
equipment housing. Failure to comply can result in damage to 
components. 



Caution 

Align only one outboard plate at a time (either upper or lower) to 
CAUTION P u * th e rollers back into factory alignment. If both plates are 

loosened, it may not be possible to align the rollers outside of the 
factory. 





3-21 



3600 Printer Maintenance Manual 



Aligning the Rollers 

You should perform this procedure every time an outboard plate is removed or 
replaced. To perform this procedure, you need the following tools: 

Note: If the printer you are servicing has upper outboard plate lntermec Part No. 
062476-002 installed, you need to replace it with a new upper outboard plate lntermec 
Part No. 063225-001 before you can perform the following roller alignment. 

• Roller alignment tool, lntermec Part No. T43150 

• #2 Phillips screwdriver 

To align the rollers 

1 . Switch off the printer power and remove the power cord. 

2. Remove the media cover, the electronics cover, and the front bezel cover 
(refer to Chapter 5, "Remove and Replace Procedures/'for detailed 
instructions). 

3. Raise the printhead with the printhead lift lever. Remove media and ribbon 
if loaded. 

4. Loosen the Phillips screws on the outboard plate that you are aligning. 

Note: Align only one outboard plate at a time (either the upper or the lower) to put 
the rollers back into factory alignment. If both plates are loosened, it may not be 
possible to align the rollers outside of the factory. 

5. Align the three holes in the roller alignment tool with the platen roller, the 
liner roller, and the TTR roller. The fourth hole in the roller alignment tool 
fits over the black plastic cap closest to the front of the printer. 




3-22 



Testing and Adjusting 




6. When the tool fits properly on all of the rollers and the bushing, tighten the 
screws on the outboard plate that you are aligning. 

7. Reattach the front bezel cover. Ensure that the media access door operates 
properly (snaps firmly shut) after the front bezel cover is installed. 

8. Install the electronics cover. 

9. Reload media (and ribbon if used). 

10. Install the media cover and the power cord. 

11. Switch on printer power and check for proper operation. 

Aligning the Printhead 

Align the printhead only if necessary. To perform this procedure, you need the 
following tools: 

• Printhead alignment tool, Intermec Part No. T43099 

• 9/64-inch Allen screwdriver 

To align the printhead 

1. Switch off the printer power. Remove the power cord and the media cover. 

2. Raise the printhead with the printhead lift lever. Remove media and ribbon. 

3. Position the printhead adjustment lever clockwise /left two clicks during 
the printhead alignment. Loosen the two Allen screws located on the 
printhead yoke at the back of the printhead heatsink. 



Printhead 

adjustment 

lever 




3-23 



3600 Printer Maintenance Manual 



Note: This is a change in procedure from previous printhead alignment 
instructions that directed the printhead adjustment lever to be in the neutral/center 
position during alignment. 

4. Install the printhead alignment tool and press the printhead assembly 
down on the platen roller. Align the tool with the notches in the heat sink 
and the printhead. 

5. Alternately tighten the two 9/64 inch printhead yoke screws until secure. 

6. Remove the printhead alignment tool. 

7. Return the printhead adjustment lever to the neutral/ center position. 

8. Reload media (and ribbon if used). 

9. Install the media cover and the power cord. 

10. Switch on printer power and test for proper printhead alignment by 
printing out the print quality and pitch labels. 



Place the cutouts 
of the printhead 
alignment tool onto 
the shaft of the platen 
roller. 



Guide pin 

(Align with the notches 

on the heatsink and printhead.) 




Printhead 
alignment 
tool 



3-24 



Testing and Adjusting 




Aligning the TTR Supply Hub 

You should align the TTR supply hub only if you are experiencing ribbon 
wrinkle on full width ribbon after the rollers and printhead have been aligned. 
To perform this procedure, you need the following tools: 

• TTR supply hub alignment tool, Intermec Part No. T43149 

• #2 Phillips screwdriver 

To align the TTR supply hub 

1 . Switch off the printer power. 

2. Remove the media cover and the electronics cover. 

3. Install the TTR supply hub alignment tool as shown. 




Ribbon supply 
hub alignment 
tool 



3600M.041 



4. Tighten the alignment tool thumbscrew so the bushing tab is flush against 
the bushing on the hub adjustment plate. 

5. Loosen the two screws securing the hub adjustment plate. 

6. Switch on the printer power. 

7. Print a series of the same kind of labels that were having the ribbon 
wrinkling problem. While they are printing, adjust the TTR supply hub up 
or down (with the thumbscrew on the tool) until ribbon wrinkling is 
eliminated. 



3-25 



3600 Printer Maintenance Manual 



Note: If this adjustment does not eliminate ribbon wrinkling, try readjusting the 
ribbon supply hub and realigning the printhead. 

8. When an alignment is achieved that eliminates the ribbon wrinkling, 
tighten the two screws on the hub adjustment plate. 

9. Remove the tool and retest for ribbon wrinkling. 

10. After the printer is correctly adjusted, switch off the power and reattach the 
electronics and media covers. 



3-26 




Troubleshooting 



Troubleshooting 




This chapter provides you with information that will help you determine why a printer 
may not be working and how to get it working again. 



About Troubleshooting and Repair 



Use the information in this chapter to identify the cause of a failing printer. It is 
assumed that a printer is not working and that the troubleshooting actions 
referenced in the user's manual were not used, failed to clear the problem, or 
pointed to a printer malfunction. 

Troubleshooting Tips 

One of your first concerns is to duplicate and isolate the problem, to confirm if 
the problem is the printer or not. Usually the printer was already working at 
some point before you were called, so start with the last time it worked and 
move forward logically, considering what might have changed since then. Do 
not neglect to check simple things like, "Is the printer plugged in? Is there 
power at the outlet? Are all of the connections good?" Spend a minute visually 
examining the unit and considering the situation to see if anything obvious 
stands out. 



Where to Start 

If you have not already done so, review the user's troubleshooting information 
in this chapter and use tests from Chapter 3, "Testing and Adjusting," to 
determine if and how the printer performs offline. If you have a working 
installation at hand, consider the value and difficulties of trying the printer in a 
known good working location. If you take this kind of action, be careful not to 
cause additional problems or confuse your search. 

If you decide you need to and can, carefully and logically swap known good 
printers, subassemblies, or components with failing or suspect items as a 
means of isolating the cause of the problem. Do not do this if you think any 
known good item can be damaged. 

Repair 

Repair is whatever action you take to eliminate the problem that you are on site 
to fix. If "repair" is the removal and replacement of a key printer component, 
refer to Chapter 5, "Remove and Replace Procedures." 



4-3 



3600 Printer Maintenance Manual 



Troubleshooting Checklist 



If the host receives an error message or a functional problem with the printer is 
encountered, the user's manual starts with the following: 

• Check whether the printer sends an error code to the host in response to a 
<BEL> command. 

• If an error code is sent, find it in the "Error Codes" table in this chapter. Try 
the solution given for the respective error code to attempt to correct the 
problem. 

• If the printer does not send an error message to the host, try to match the 
symptom of your failure in the "Printer Operation Problems" or "Print 
Quality Problems" tables in this chapter. Try the solution given for the 
respective symptom to attempt to correct the problem. 

• Clean the printer components and check all connections. 



4-4 



Troubleshooting 




Error Handling 



This section describes how the 3600 printer handles certain error conditions it 
may encounter in printer or programming commands. Error codes sent to the 
host, the problem the code is reporting, and the usual solution are listed in a 
table at the end of this section. 



Syntax Errors 

The 3600 printer responds to syntax errors in the messages it receives from the 
host by attempting to execute the commands. It does not ignore a command 
with a syntax error. Instead, the printer produces output, even if it is 
erroneous, which gives you an indication of what went wrong and what 
should be done to correct the problem. 

Parameter Errors 

Certain commands require optional parameters. If these parameters are not 
supplied, default values are substituted. If a parameter is above its maximum 
range limit, the maximum value is used. If it falls below the minimum range, 
the minimum value is used. The range and the default value for each command 
are listed in Chapter 6 of the user's manual. 

Image Overrun Errors 

Image overrun occurs when a label is too complex to image for a given print 
speed. An overrun will cause the printer to abort the label being printed. This 
error is most common on labels over 5 inches long. 

The printer automatically attempts to correct for this error condition by 
resetting to the lowest print speed and to the highest number of image bands, 
and then repeats printing the label. The printer remains at this setting until you 
reset it. If an image overrun still occurs, printing for that batch of labels stops 
and any following commands are executed. 

Installing the optional 512K memory expansion prevents image overrun errors. 



4-5 



3600 Printer Maintenance Manual 



Invalid Numeric Character Errors 

If non-numeric characters are included within a numeric data string in a 
command, the printer disregards them and continues to process the rest of the 
valid numeric characters. However, if a non-numeric character begins the 
numeric data string, the printer uses a default value for the affected command. 

Here are two examples of valid numeric character strings and one example of 
an invalid string: 

12a valid 

la2 valid 

al2 invalid 

Insufficient Storage RAM Errors 

Before storing new formats, graphics, or user-defined fonts in the static RAM, 
the printer checks to see if it has sufficient memory to store them. If there is 
insufficient memory, the last editing session is disregarded. The printer is 
designed to preserve the integrity of the existing data in the static RAM. 

Error Codes 

Most of the problems you may encounter cause the 3600 printer to send an 
error code to the host. When this happens, find the error code in the following 
table and try the solution given to attempt to correct the problem. 



4-6 



Troubleshooting 




Printer Errors 



Error Code Problem 

00 No error. 

01 Invalid bar code check character. 



02 
04 
05 

06 

07 

08 

11 
12 

13 
21 

22 

23 

24 

25 

26 

27 

28 



Invalid number of bar code 
characters (Code UPC/EAN). 

Bar code check character within 
numeric field marks. 

Supplemental delimiter within 
numeric field marks (Code 
UPC/EAN). 

Invalid supplemental character 
count (UPC/EAN). 

More than one supplemental 
delimiter (Code UPC/EAN). 

Invalid start /stop characters 
(Codabar). 

Invalid bar code data. 

Data count exceeded. 

Entering data in non-data entry field. 
Quantity or batch count out of range. 

Field increment/ decrement out of 
range. 

Intercharacter/ message delay out of 
range. 

Missing preamble/postamble data. 
Invalid format transmission syntax. 
Invalid page transmission syntax. 
Invalid font transmission syntax. 
Invalid UDC transmission syntax. 



Solution 



Verify the bar code check character modifier used in the 
bar code program command. 

Verify the number of bar code characters used in the bar 
code program command. 

Check the bar code program command for accuracy. 



Check the bar code program command for accuracy. 



Check the bar code program command for accuracy. 



Check the bar code program command for accuracy. 



Verify start and stop characters in the label format. 



Verify data in the label format. 

Data count should not exceed what is specified for the 
field. 

Check the field for accuracy. 

Quantity of labels or number of batches should be 
between 1 and 9999. 

Quantity should be between 1 and 9999. 



Delay should be between and 9999. 

Delete the setup for preamble or postamble data, or 
include the data. 

Check the format transmission syntax. The correct 
syntax is <ESC>xjnj with n ranging from to 19. 

Check the page transmission syntax. The correct syntax 
is <ESC>y{n( with n ranging from to 9. 

Check the font transmission syntax. The correct syntax 
is <ESC>v{n| with n ranging from to 24. 

Check the UDC transmission syntax. The correct syntax 
is <ESC>u{n( with n ranging from to 99. 



4-7 



3600 Printer Maintenance Manual 



Printer Errors (continued) 
Error Code Problem 

32 



33 

34 
35 
36 

37 

38 
41 

42 



43 

46 

52 

53 
54 



Non-immediate command or data 
received after buffer full. 

Invalid field delimiters. 



Invalid escape command. 

Invalid data shift command. 

Invalid or undefined format 
number. 

Insufficient room in RAM to print 
format. 

Invalid or undefined field number. 

Syntax error for program 
commands. 

Insufficient room in RAM to store 
format. 



Too many fields in label format. 



Undefined statement. 

Invalid UDC/UDF bitmap cell 
height/width or intercharacter 
space. 

Insufficient room in RAM to store 
UDC or UDF. 



Solution 

Allow the printer to empty the buffer contents before 
sending commands or data. 

Check for all pairs of field delimiters, and make sure both 
are numeric or both are alphanumeric. 

Correct the escape command syntax. 

Correct the shift command syntax. 

Verify that the format numbers are between and 19. 

Reduce the number of data fields in the format. 

Verify the field number in the label format. 
Check the program command for proper syntax. 

Empty the buffer contents. If the format still does not fit, 

delete some fields or other data from the format. You may 

have to remove or reduce the UDCs, formats, or fonts if 

necessary. 

Note: Entering <ESC>m tells the host how much memory is 

installed and how much is available. 

You can use up to 200 fields in a format and each field can 
use up to 250 characters. Reduce field size or delete some 
fields. 

Check the statement syntax. 

Verify that cell heights and widths are between 1 and 599, 
and that the intercharacter space is between and 199. 

Remove or reduce formats, fonts, or UDCs. 



Invalid UDC command syntax. Correct the UDC command syntax. 



4-8 



Troubleshooting 




Printer Operation Problems 



Symptom 

No power or loss of 
power. 



Labels stop feeding 
through the printer. 



Printer slows down. 



If a printer is not operating correctly, try locating the problem and 
implementing the solution from the following table: 



Labels stick to door or 
fail to strip. 

The stepper motor 
stalls while printing 
media that is less than 
6.6 inches wide. 

Configuration label 
does not print. 



Possible Causes 

AC power cable is damaged or 
disconnected. 



Printer circuit breaker tripped. 



Power supply function is failing. 



Printer is out of media. 



Solution 

Make sure the power cable is plugged into both 
the printer and an outlet or power strip. Replace 
the cable if it is damaged. 

Turn the printer off and then back on again 
(determine why it tripped). Replace circuit 
breaker if defective. 

Check the transformer and the main PCB. 
Replace whichever is defective. 

Load new media. 



Label stock is loaded incorrectly. Check the media path. 



Media is sticking to the paper 
path. 

Printer is set for continuous label 
stock. 



Label sensor(s) dirty, out of 
adjustment, or failing. 

Image bands or print speed are 
incorrectly set. 

Printer has aborted and print 
speed and image bands were 
reset. 

The self -strip roller is dirty or the 
pinch roller is not contacting the 
strip roller. 

The bias is not adjusted properly. 



Clean any extraneous material from the paper 
path and clean it thoroughly. 

Use the Transmit Configuration Parameters 
<ESC>p command to check the configuration 
setting. Select the correct setting with the Select 
Label Stock Type command (<SI>T). 

Clean and adjust, or replace the sensor(s) as 
required. 

Change the image bands or print speed settings. 



Change the image bands or print speed settings. 



Clean the self -strip roller. 



Adjust the bias adjust screw to the optimum 
printing position. 



The media is loaded incorrectly. Try reloading the media. 



4-9 



3600 Printer Maintenance Manual 



Print Quality Problems 



If labels are not printing properly, try locating the problem and implementing 
the solution in the following table: 



Symptom 

Blotches on labels. 



Printing is too light or 
too dark. 



Printing not aligned 
on label. 



Labels are not 
stopping at the right 
point to be removed. 



Possible Causes 

Dirty printhead. 

Dirty media path or rollers. 

Poor quality label or ribbon 
stock. 



Darkness adjust control is set 
incorrectly. 

Poor quality label or ribbon 
stock. 



Sensitivity number is set 
incorrectly. 

Dirty printhead. 

The printhead adjustment lever 
is not positioned as needed. 

Printer is misfeeding media. 

Platen roller and/or printhead 
out of alignment. 

Label rest point command is 
incorrectly set. 

Printer is set for continuous label 
stock. 



Solution 

Clean the printhead. 

Clean the media path. 

Use only Intermec label and ribbon stock to 
ensure superior print quality and product 
performance. 

Adjust the knob to achieve the best print quality. 

Use only Intermec label and ribbon stock to 
ensure superior print quality and product 
performance. 

Change sensitivity setting to match the type of 
media being used. If sensitivity is set correctly, 
try changing the dark adjust command. 

Clean the printhead. 

Reposition the printhead adjustment lever. 

Make sure that media is installed properly along 
the entire media path. 

Perform roller alignment first and then 
printhead alignment. 

Adjust the label rest point. 



Set the printer for proper label stock; either gaps 
or marks. 



4-10 



Troubleshooting 




Symptom 

Print quality is poor. 



Possible Causes 

Incorrect media sensitivity. 



The darkness of label print is too 
light or too dark. 

Printhead, platen roller, or label 
path are dirty. 

Uneven print contrast (density). 

Incorrect label or ribbon stock is 
used to print labels. 

Ribbon wrinkling. 



Ribbon installed upside down. 

Direct thermal /thermal transfer 
switch set in the wrong position. 

Printhead or platen roller is 
severely worn. 

Media may be slipping against 
the platen roller causing the 
printing to compress. 



Solution 

Change sensitivity setting to match the type of 
media you are using. If sensitivity is set 
correctly, try changing the dark adjust. 

Properly set the darkness adjust control. 



Clean printhead, platen roller, and label path. 



Adjust the bias adjust screw. 

Use only Intermec label and ribbon stock to 
ensure superior print quality and product 
performance. 

Check to make sure that the ribbon is installed 
correctly. 

Check the following alignments in the sequence 
given, testing for elimination of the problem 
before performing the next alignment. 
Note: Making these adjustments out of order can 
introduce and not solve printing problems. 

1) Roller alignment 

2) Printhead alignment 

3) Ribbon supply hub alignment 

Install ribbon with shiny side facing the 
printhead. 

Set the switch for the type of media being used. 



Replace the platen roller or printhead. 

Switch to approved media or clean the 
printhead and platen. 



4-11 



3600 Printer Maintenance Manual 



Communications Problems 



If a printer is not receiving downloaded data, consider the causes and solutions 
in this section. 



Symptom 

Printer does not 
communicate with the 
host. 



Possible Causes 

Serial port is incorrectly 
configured. 



Disconnected, damaged, or 
incorrect I/O cable. 



Solution 

Make sure the printer's serial port settings 
match those of the host. Print a software test 
configuration label to check the serial port 
settings. 

Check the connections at both ends. Replace the 
cable if necessary. 



Any loss of data can cause printing errors or missing data. The 3600 printer is a 
serial ASCII device that communicates with the host through an ASCII serial 
communications port. The two devices communicate through the use of 
hardware and software protocols (handshaking). The printer utilizes both 
forms of handshaking simultaneously when the printer's input buffer is full. 
Consider this process when troubleshooting. 

Hardware handshaking uses pins 11 or 20 of the RS-232 interface to control 
data flow. When the printer is using Intermec "Standard" protocol, pin 11 and 
20 are held high when the printer is ready to receive data. The pins are held 
low when the printer is in one of the following conditions: 

• Buffer full 

• Ribbon fault 

• No label stock 

• Label at strip pin 

The 3600 printer uses XON/XOFF protocol for software handshaking. When 
the input buffer is full, the printer transmits an XOFF character. This character 
alerts the host to the fact that the printer buffer is full and cannot receive any 
more data. When the printer is ready to receive more data, it sends the XON 
character. 



4-12 



Troubleshooting 



To check for communications problems 

1 . Check the cabling from the printer to the host system. 

2. Check the interfacing of the devices that are communicating with the 
printer. 

3. Check the printer for proper electrical operation of the serial 
communications port. 

4. Test to see that the host system is not overrunning the printer's input 
buffers. 

5. Check to see that the data string being sent to the printer contains the 
correct information. 




Environmental Problems 



Symptoms associated with environmental problems are printing garbage, 
resetting, or total lockup. One way to discover if the problem is environmental 
is to see if the problem goes away when the printer is moved to a new location. 
If it shows up in a printer recently moved from another area, the problem is 
probably environmental. The following is a discussion of different types of 
environmental problems. 

Electrostatic Discharge (ESD) 

ESD can cause failure or weakening of affected components. Typically, ESD 
occurs when a person with a large electrical potential unintentionally 
discharges that potential by touching the conductive surfaces of the equipment. 
Static charge is created through friction from people walking, conveyor belts, 
paper moving through a printer, and wheelchairs. The solution is to reduce the 
charge by grounding and by employing prevention measures such as antistatic 
bags for ICs and PCBs, grounded antistatic mats, antistatic spray for carpeting, 
antistatic clothing (no wool), antistatic wax for tile floors, conductive floor 
materials, air ionizers, and antistatic cleaners for plastics. To further protect 
against ESD, use shielded cable for interface cables, and tie the shield to metal 
backshells at both ends of the cable. Do not connect the shield of the cable to 
the chassis ground or signal ground of the interface (metal backshells will be 
tied to the chassis). 



4-13 



3600 Printer Maintenance Manual 



Electromagnetic and Radio Frequency Interference 

Noise induced in interface cables can result in the printer receiving false data. 
This condition may cause the printer to skip printing a label or lockup. Sources 
of electromagnetic interference (EMI) and radio frequency interference (RFI) are 
radio transmitters, ignition systems, and relays. To eliminate the effects of EMI 
and RFI, use low capacitance, twisted pair, shielded cables. Route cables away 
from sources of EMI and RFI such as large inductive motors or fluorescent 
lighting ballasts. Do not run cables near AC power lines. If communication 
cables must run near AC power lines, cross them at 90 degree angles. Eliminate 
ground loops; they act as receiving antennas for RFI. Limit the number of 
breaks (connectors) in the cable. It is possible to use a power line monitor, such 
as the BMI 4800, to test for noise on the interface cable. 

Ground Loops Between Equipment 

Ground loops pick up RFI as well as generate their own noise in interface 
cables. The recommended wiring of the interface cable calls for connecting 
chassis ground (pin 1) between the host computer and the printer to ensure 
that the chassis of both devices remains at the same electrical potential in the 
event of a faulty ground in either device. This safety precaution will save 
people from electric shock in the situation where they touch both the host 
computer and the printer at the same time while there is a faulty ground in 
either device. With this wiring, you would normally expect problems with 
ground loops, but the printer, chassis ground, and signal ground are connected 
to each other through a lOkQ. resistor, thus providing some ground loop 
immunity. 

If connections in the interface cable described above are discovered to cause 
ground loop problems, disconnect the shield from the backshell at only the 
printer, and sever the chassis ground (pin 1) connection between the host 
computer and the printer. To ensure safety, double your efforts to guarantee 
that both the host computer and the printer make a solid electrical and physical 
connection to earth ground. 

Inadequate Earth Ground 

Poor grounds can cause fuses on equipment to blow and damage components. 
The ground in the AC power receptacle must be a good, solid earth ground. Do 
not rely on conduit for ground. The ground rod should penetrate the earth at 
least 8 feet below the frost line. The soil should contain clay minerals; dry, 
sandy soil does not provide a good ground. Ensure that all ground connections 
from the service panel to the AC receptacle are solid and secure. 



4-14 




Troubleshooting 



AC Power Problems (Surges, Sags, Spikes, Noise, and Outages) 

Most environmental problems involve the AC power line. In the 3600 printer, 
115V supply voltages can range from 90 to 132 VAC. Outside the U.S., 230V 
supply voltages can range from 180 to 264 VAC. Voltage overages or 
underages can result from poor utility regulation to in-plant loading of the 
power service. Use a power line monitor, such as the BMI 4800, to look for 
power service problems. To eliminate the effects of voltage overages and 
underages, install an uninterruptible power supply (UPS) or install a dedicated 
circuit for the printer and the host computer. 

Intermittent power outages can be caused by a combination of vibration and 
loose connections between the service panel and the AC receptacle. Check the 
wiring to ensure that all connections are solid and secure. Use a power line 
monitor to test for outages. To eliminate the effects of power outages, install a 
UPS. 

Impulse noise on the power line can also cause the printer to lockup or reset. 
All Intermec products, including the 3600 printer, meet IEC 801, Surge and 
Burst specifications. Impulses can range from 200 to 5000V and are caused by 
lightning, switching operations, firing of SCRs, triacs, static discharge, and arc 
welders. Use a power line monitor to verify the presence of impulse noise, and 
use a spike suppressor to eliminate its effect. 

Irregular sine waveforms on the AC power line can also affect printer 
performance. They are caused by switching power supplies. Use a power line 
monitor to verify the presence of irregular sine waveforms and use a power 
line conditioner to eliminate their effects. 

High frequency noise and hash riding on the AC waveform can affect printer 
performance. They are caused by transmitters and ignition systems. Use an 
oscilloscope to verify the presence of noise and hash. Install EMI/RFI filters to 
eliminate their effects. 

To troubleshoot environmental problems 

1 . Correlate an environmental event with the failure. 

2. Check for static discharges. 

3. Check for adequate grounding. 

4. Check the AC power for proper level and purity. 

5. Check for inductive motors, relays, or other spike inducing equipment on 
the power line. 

6. Exercise good judgment and common sense. 



4-75 



3600 Printer Maintenance Manual 



Miscellaneous Problems 



The following information identifies some possible printer problems and what 
might be their cause. 

• Problems with printer-to-computer communications, motor control, or 
media advance may be caused by a faulty main PCB assembly. 

• If information downloaded to the printer memory is lost after the printer is 
powered off (lost data includes configuration setting changes reverting to 
their factory defaults when power is cycled), the lithium battery may be 
bad. 

• The appearance of long white streaks in printed labels indicates a dirty 
printhead or possible printhead failure. 

• If you have problems with the bezel LEDs or the Feed/Pause button, you 
may need to replace the bezel PCB assembly. 

• If the printer no longer registers the use of marked label stock, you may 
need to replace the label mark sensor. 

• Light print on one side of a label can occur if the printhead is not making 
even contact with the media. This condition can happen with any size 
media, but is most common when using narrow labels where there is no 
media between the printhead and the platen roller. Uneven lateral print 
darkness may be eliminated by adjusting the bias screw. 

If the printer is no longer sensing when labels have been removed, you may 
need to adjust or replace the label taken sensor. 

If the TTR takeup hub fails to roll up ribbon, you may need to replace the 
upper drive belt and/or the TTR takeup clutch. 

If a ribbon fault occurs when the printer is in the TTR mode, you may need 
to replace the TTR encoder sensor. 

If the liner takeup hub discontinues rolling up liner, you may need to 
replace the liner takeup (lower) drive belt or clutch. 

If the platen roller does not turn but the liner drive roller does, you may 
need to replace the platen roller gear. 

If none of the rollers turn, you may need to replace the stepper motor. 



4-16 




Remove and Replace Procedures 



Remove and Replace Procedures 




This chapter contains illustrated instructions for removing and replacing key 
components of the 3600 printer. 



Replacing Printer Components 



When a printer component needs replacing, use the appropriate following 
procedure. See Chapter 7, "Replacement Parts," for a complete list of spare 
parts. 

After replacing a component, refer to Chapters 2 and 3 for the procedures to 
complete the repair by ensuring that you leave the printer performing at its 
optimum level. 

Prior to taking any action, review all warnings, cautions, and procedures 
associated with any component you intend to remove. 

When performing any of the procedures in this chapter, heed the following 
warnings and cautions at all times to avoid the consequence identified. 

A Warning 

Always disconnect the power cord before removing the electronics 
WARNING cover unless the procedure requires the unit be energized. Failure to 

disconnect the power cord may result in injury or death due to 
electric shock. 



Caution 

The printhead and integrated circuits on printer circuit boards in 
CAUTION ^is equipment are sensitive to damage by electrostatic discharge 

(ESD). Prevent ESD by always wearing skin contact ground straps 
firmly attached to the equipment metal base assembly when 
working inside of the equipment housing. Failure to comply can 
result in damage to components or the printhead. 



Caution 

Do not remove the motor plate or subplates. Changing the position 
CAUTION of the motor plate can alter factory alignment and cause ribbon 

wrinkling or liner-stripping problems. 





5-3 



3600 Printer Maintenance Manual 



Replacing the Lithium Battery 



To replace the lithium battery, you will need the following parts and tools: 

• 1.75AH 3.6V AA lithium battery, Intermec Part No. 586229 

• ESD grounding strap 

• #2 Phillips screwdriver 



A 

WARNING 



Warning 

There is danger of explosion if the battery is incorrectly replaced. Replace 
it only with the same or equivalent type battery recommended by the 
manufacturer. Discard used batteries according to the manufacturer's 
instructions. 

II y a danger d 'explosion s'il y a remplacement incorrect de la batterie. 
Remplacer uniquement avec une batterie du meme type ou d'un type 
recommande par le constructeur. Mettre au rebut les batteries usagees 
conformement aux instructions du fabricant. 



To replace the lithium battery 

Note: The printer will lose data if the battery fails or is removed. Before removing the 
battery, upload and save the fonts, formats, pages, graphics, and configuration settings. 

1 . Switch off the printer power and remove the power cord, the media cover, 
and the electronics cover. 

2. Remove the old battery and install the new battery, matching the (+) and (-) 
ends of the battery with the (+) and (-) signs on the main PCB. 



Lithium 
battery 




3. Install the covers and power cord. Check the printer for proper operation. 



5-4 



Remove and Replace Procedures 




Replacing the Printhead 



To replace the printhead, you will need the following parts and tools: 

• 6.6-inch 5 mil printhead, Intermec Part No. 061611S-001 

• ESD grounding strap 

• Medium straight-slot screwdriver 

To replace the printhead 

1 . Switch off the printer power and remove the power cord. 

2. Remove the media cover. 

3. Raise the printhead. Remove media and ribbon if loaded. 

4. Release the locks on the printhead cable by pressing in on each side of the 
cable connector. Remove the printhead cable. 

Note: If you need slack to separate the printhead and cable, unplug the cable from 
the main PCB and pull some of it through the cutout in the main deck plate. 



Printhead 

retaining 

screw 



Straight slot 
screwdriver 



Cable 
connector 




Printhead 
cable 



Printhead 



5-5 



3600 Printer Maintenance Manual 



5. Use a straight-slot screwdriver to loosen the printhead retaining screws, 
located in the center of the printhead heatsink. The screw is easier to loosen 
if you place one of your fingers underneath the printhead, between the 
printhead and the platen roller. Pull the printhead away from the printer 
(since it is a tight fit, you may need to pull it out from the outboard side 
rather than from the front). 

6. Replace the printhead and cable and tighten the printhead retaining screws. 

7. Reload media (and ribbon if used) and lower the printhead. 

8. Install the media cover and the power cord and check the printer for proper 
operation. 



Replacing the Bezel PCB 



To replace the bezel PCB, you will need the following parts and tools: 

• Bezel PCB assembly, Intermec Part No. 059052S-001 

• ESD grounding strap 

• #1 and #2 Phillips screwdrivers 

To replace the bezel PCB assembly 

1 . Switch off the printer power and remove the power cord. 

2. Remove the media cover and the electronics cover. 

3. Unplug the bezel PCB assembly from the main PCB and remove the five 
screws that hold the front bezel cover to the printer. 




Front bezel 
cover 



5-6 



Remove and Replace Procedures 




4. Lift the front bezel cover away from the printer and lay it on a flat surface. 

5. Use the #2 Phillips screwdriver to remove the two screws that hold the 
bezel PCB/ cover plate assembly to the front bezel cover. 

6. Being careful not to break the switch stem or the button cap, pull the 
Feed/Pause button cap off of the switch on the bezel PCB. Retain the 
yellow button cap for installation onto the replacement bezel PCB. 

7. Use the #1 Phillips screwdriver to remove the two screws securing the bezel 
PCB to the front cover plate. 



Bezel PCB 
assembly 



Yellow 
button 
cap 



Front cover 
plate 




Front bezel 
cover 



8. Use the #1 Phillips screwdriver to attach the replacement bezel PCB to the 
front cover plate. 

9. Carefully press the yellow button cap removed in Step 6 onto the switch on 
the replacement bezel PCB. 

10. Attach the bezel PCB front cover plate assembly to the front bezel cover. 

11. Reattach the front bezel cover to the printer. Ensure that the media access 
door operates properly (snaps firmly shut) after the front bezel cover is 
installed. Connect the cable. 

12. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-7 



3600 Printer Maintenance Manual 



Replacing the Main PCB 



To replace the main PCB, you will need the following parts and tools: 

• 3600 main PCB assembly, Intermec Part No. 061591S-005 or 06159E-005 

• ESD grounding strap 

• #2 Phillips screwdriver 

To replace the main PCB assembly 

1. Switch off the printer power and remove the power cord, the media cover, 
and the electronics cover. 

2. Unplug all of the cables from the main PCB and remove the seven screws 
securing the main PCB to the printer to remove the main PCB. Do not place 
the printer on its side as this may disturb alignments. 



Main PCB 
assembly 




3. If the main PCB you are replacing has the 512K SRAM memory expansion 
chip, verify that the new main PCB is similarly equipped. If it is not, 
carefully unplug the existing 512K chip and plug it into the new main PCB 
before installing it. 

4. If the main PCB you are replacing has a Kanji/Katakana option PCB 
installed, use the next procedure to relocate the Kanji/Katakana option PCB 
to the new main PCB before installing it. 

5. Install the new main PCB, securing it with the seven screws removed in 
Step 3, and connect all of the cables. 

6. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-8 



Remove and Replace Procedures 




Replacing the Kanji/Katakana Option PCB 

To replace a Kanji/Katakana PCB, you will need the following parts and tools: 

• 3600 Kanji/Katakana PCB, bitmap font, Intermec Part No. 060689-001 or 
3600 Kanji/Katakana PCB, outline font, Intermec Part No. 060690-001 

• ESD grounding strap 

• #2 Phillips screwdriver 

To replace the Kanji/Katakana PCB 

1 . Switch off the printer power and remove the power cord, the media cover, 
and the electronics cover. 

2. Remove the screws that secure the Kanji/Katakana PCB to the main PCB. 




PCB stacking 
spacer 



Kanji/Katakana PCB 



3600M.047 



5-9 



3600 Printer Maintenance Manual 



3. Unplug the Kanji/Katakana PCB from the main PCB using a gentle rocking 
motion while pulling it away. 

4. Install the new Kanji/Katakana PCB onto the main PCB, making sure the 
pins are properly aligned with the connector and that the Kanji/Katakana 
PCB is fully seated before tightening the screws. 

5. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



Replacing the Label Mark Sensor 



To replace the label mark sensor, you will need the following parts and tools: 

• Label mark sensor cable assembly, Intermec Part No. 061578-001 

• Roller alignment tool, Intermec Part No. T43150 

• ESD grounding strap 

• #1 and #2 Phillips screwdriver 

To replace the label mark sensor 

1 . Switch off the printer power and remove the power cord. 

2. Remove the media cover, the electronics cover, and the front bezel cover 
(refer to "Replacing the Bezel PCB" earlier in this chapter). 

3. Raise the printhead. Remove media and ribbon if loaded. 

4. Remove the screws securing the lower outboard plate to the printer and 
pull it away from the printer. Retain the tear bar and tear bar support. 



Tear bar 




Tear bar 
support 



Lower outboard 
plate 



3600M.048 



5-10 



Remove and Replace Procedures 




Disconnect the label mark sensor cable from the main PCB, remove the 
cable from the two plastic clips, and push it through the cutout in the main 
deck plate. Slide the sensor out from the extrusion. Remove the cable from 
the plastic cable clip on the extrusion. 




Label mark 
sensor 



6. Insert the new label mark sensor into the extrusion. Route the cable 
through the plastic cable clip on the extrusion and through the cutout in the 
main deck plate, and then plug it into the main PCB. Secure the cable in 
place by inserting it into the two cable clips. Any slack in the cable should 
be arranged between the sensor and the cable clip on the extrusion. There 
should be no slack cable on the electronics side of the printer. Make sure 
the cable is secure and not contacting any moving parts. 

7. Reassemble the tear bar and bar support and install the lower outboard 
plate, capturing the tear bar, liner drive roller, and platen roller. 

Note: Use the roller alignment tool during reassembly for proper alignment of the 
outboard plate. 

8. Reattach the front bezel cover. Ensure that the media access door operates 
properly (snaps firmly shut) after the front bezel cover is installed. 

9. Reload media (and ribbon if used) and lower the printhead. 

10. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-11 



3600 Printer Maintenance Manual 



Replacing the Label Taken Sensor 



To replace the label taken sensor, you will need the following parts and tools: 

• Label taken sensor cable assembly, Intermec Part No. 059496-002 

• ESD grounding strap 

• #1 and #2 Phillips screwdriver 

To replace the label taken sensor 

1 . Switch off the printer power and remove the power cord. 

Remove the media cover, the electronics cover, and the front bezel cover 



2. 

3. 
4. 



(refer to "Replacing the Bezel PCB" earlier in this chapter). 

Raise the printhead. Remove media and ribbon if loaded. 

Disconnect the label taken sensor cable from the main PCB, remove the 
cable from the two plastic clips, and push it through the cutout in the main 
deck plate. Slide the sensor housing away from the main deck plate. 



Main 
deck 
plate 



Label taken 
sensor 




Install the new sensor, routing the cable through the cutout in the main 
deck plate and plugging it into the main PCB. Place the cable in the plastic 
clips with the black sleeve positioned as close as possible to the sensor end. 

Reattach the front bezel cover. Ensure that the media access door operates 
properly (snaps firmly shut) after the front bezel cover is installed. 

Reload media (and ribbon if used) and lower the printhead. 

Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-12 



Remove and Replace Procedures 




Replacing the Label Gap Sensor 



To replace the label gap sensor, you will need the following parts and tools: 

• Label gap cable assembly, Intermec Part No. 059495-001 

• ESD grounding strap 

• Small straight-slot screwdriver 

• 12-inch shank #2 Phillips screwdriver 

To replace the label gap sensor 

1. Switch off the printer power and remove the power cord, the media cover 
and the electronics cover. 

2. Raise the printhead. Remove media and ribbon if loaded. 

3. Disconnect the label gap sensor cable from the main PCB. 




Upper and lower 
media guide assembly 



Gap sensor 
cable 



Label gap 
sensor ^ 

#1 



3600M.051 



4. Remove the three screws securing the upper/lower media guide assembly 
to the main deck plate. 

5. Slide the upper media guide outward to separate it from the rest of the 
assembly. 



5-13 



3600 Printer Maintenance Manual 



Upper 
media 
guide 




Label gap 

sensor 

housing 



Lift spring 



6. Use a small straight-slot screwdriver to lift up on each of the two molded 
tabs that secure the label gap sensor. Slide the label gap sensor from its 
housing and replace it with the new label gap sensor. The label gap sensor 
should snap into place. 

7. Slide the upper media guide plate back together with the lower media 
guide plate. 

8. Route the label gap sensor cable through the cutout in the main deck plate 
and reattach the media guide assembly to the frame. Be sure that the media 
brake arm does not rub on the upper media guide and that the sensor cable 
is not contacting any moving parts. 

9. Attach the label gap sensor cable to the main PCB. 

10. Reload media (and ribbon if used) and lower the printhead. 

11. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-14 



Remove and Replace Procedures 




Replacing the TTR Drive Roller and Gear/Pulley 

To replace the TTR drive roller or the TTR drive gear/pulley or both, you will 
need some or all of the following parts and tools: 

• TTR drive roller, Intermec Part No. 061543-002 

• TTR drive gear/pulley, Intermec Part No. 061563-002 (white) 

• Retaining E-rings, Intermec Part No. 501401 

• Retaining snap ring, Intermec Part No. 501409 

• Roller alignment tool, Intermec Part No. T43150 

• ESD grounding strap 

• Snap ring pliers 

• Needlenose pliers 

• #1 and #2 Phillips screwdriver 

To remove the TTR drive roller and TTR drive gear/pulley 

1 . Switch off the printer power and remove the power cord. 

2. Remove the media cover, the electronics cover, and the front bezel cover 
(refer to "Replacing the Bezel PCB" earlier in this chapter). 

3. Raise the printhead. Remove media and ribbon if loaded. 

4. Unloop the drive belt (O-ring) from the TTR drive gear/pulley. 



TTRtakeup ^ /£ 
drive belt y /r! "- 



TTR drive 
roller 




x Motor 
plate 



j^WI Washer 

Washer 
E-ring 



5-15 



3600 Printer Maintenance Manual 



Remove the TTR drive gear/pulley retaining E-ring. Retain the washer 
located between the E-ring and the TTR drive gear/pulley. Discard the old 
E-ring. 

Remove the retaining snap ring that secures the printhead lift lever to the 
cam assembly shaft. Pull the printhead lift lever off of the printhead lift 
shaft. Discard the old snap ring. 



Washer E-ring 

Washer 



TTR drive 
' roller 



E-ring \ 



Cam assembly 
shaft 



Printhead 
spring 




, Snap ring 

lever r a 



Unhook the printhead spring from the upper outboard plate and remove 
the screws securing the plate to the printer. Pull the plate away, freeing up 
the TTR drive roller (and the TTR shaft, printhead pressure cam assembly, 
and pivot block). 

Remove the TTR drive roller, sliding the gear /pulley off of the roller shaft. 
Retain the washer located between the roller and the main deck plate and 
the washer located between the gear/pulley and the main deck plate. 

You can now replace either the TTR drive roller, the TTR drive gear/pulley, 
or both. 



5-16 




Remove and Replace Procedures 



To replace the TTR drive roller and TTR drive gear/pulley 

1. Position the TTR drive gear /pulley with the correct washer installed 
between the gear/pulley and the main deck plate. 

2. Insert the TTR drive roller with a new retaining E-ring and the other 
washer through the main deck plate and into the gear /pulley. 

3. Install the upper outboard plate, making sure that the printhead spring is 
in place on the pivot block and that all four shafts are securely inserted into 
their correct positions in the plate. 

Note: Use the roller alignment tool during reassembly for proper alignment of the 
outboard plate. 

4. Hook the printhead spring around the upper plate. 

5. Install the printhead lift lever and secure it with a new retaining snap ring. 

6. Secure the TTR drive gear/pulley on the roller shaft with a new retaining 
E-ring and the washer you removed in Step 5. 

7. Fit the loose end of the TTR drive belt over the TTR drive gear/pulley. 

8. Reattach the front bezel cover. Ensure that the media access door operates 
properly (snaps firmly shut) after the front bezel cover is installed. 

9. Reload media (and ribbon if used) and lower the printhead. 

10. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-77 



3600 Printer Maintenance Manual 



Replacing the TTR Takeup Hub, Clutch/Pulley, and Belt 

To replace the TTR takeup hub, TTR takeup clutch/pulley, and TTR takeup 
drive, you will need some or all of the following parts and tools: 

• TTR takeup hub, Intermec Part No. 061562-005 

• TTR takeup clutch assembly, Intermec Part No. 062927S-001 (white) 

• 2.800ID x .210 drive belt (O-ring), Intermec Part No. 501462-003 

• Retaining snap rings, Intermec Part No. 501410 

• ESD grounding strap 

• Snap ring pliers 

• #1 and #2 Phillips screwdriver 

To remove the TTR takeup hub, TTR takeup clutch/pulley, and TTR drive belt 

1 . Switch off the printer power and remove the power cord. 

2. Remove the media supply cover, the electronics cover, and the front bezel 
cover (refer to "Replacing the Bezel PCB" earlier in this chapter). 

3. Raise the printhead. Remove media and ribbon if loaded. 

4. Remove the two TTR takeup clutch/pulley retaining snap rings and the 
thick washer from the end of the TTR takeup hub shaft. Retain the washer. 
Discard the old snap rings. 



TTR takeup 
drive belt 



TTR clutch/ 
■"pulley 



Thick 
washer 



Snap ring 



TTR takeup 
hub 




TTR drive 
gear/pulley 



5-18 




Remove and Replace Procedures 



5. Pull out on the TTR takeup hub to release the clutch/pulley assembly. 
Retain the thin washer located between the TTR takeup hub and main deck 
plate. 

6. Remove the TTR takeup clutch/pulley assembly and TTR drive belt. 

Note: Do not remove the motor plate or subplates. Changing the position of these 
plates can alter factory alignment and cause ribbon wrinkling or self-strip 
problems. 

7. Replace the TTR takeup hub, the TTR takeup clutch/pulley assembly, the 
TTR drive belt, or any combination of them now. 



To replace the TTR takeup hub, TTR takeup clutch/pulley, and TTR drive belt 

1. Wrap the TTR drive belt around the TTR takeup clutch/pulley, positioning 
the assembly so that the TTR takeup hub shaft can be inserted into the 
clutch/pulley. 

2. Install the TTR takeup hub with the thin washer removed in Step 5 above. 

3. Install the thick washer removed in Step 4 and the two new retaining snap 
rings to secure the TTR takeup components in place. 

4. Loop the loose end of the TTR drive belt around the TTR drive gear\pulley. 

5. Reattach the front bezel cover. Ensure that the media access door operates 
properly (snaps firmly shut) after the front bezel cover is installed. 

6. Reload media (and ribbon if used) and lower the printhead. 

7. Install the electronics cover and the media cover. 

8. Install the power cord and check the printer for proper operation. 



5-19 



3600 Printer Maintenance Manual 



Replacing the TTR Supply Hub and Adjusting Plate 

To replace the TTR supply hub, the TTR supply hub adjusting plate, or both 
parts, you will need some or all of the following parts and tools: 

• TTR supply hub, Intermec Part No. 061562-004 

• TTR supply hub adjusting plate, Intermec Part No. 062603-001 

• Retaining snap rings, Intermec Part No. 501410 

• Ribbon supply hub alignment tool, Intermec Part No. T43149 

• ESD grounding strap 

• Snap ring pliers 

• #1 and #2 Phillips screwdriver 

To remove the TTR supply hub and TTR supply hub adjusting plate 

1 . Switch off the printer power and remove the power cord. 

2. Remove the media cover, the electronics cover, and the front bezel cover 
(refer to "Replacing the Bezel PCB" earlier in this chapter). 

3. Raise the printhead. Remove media and ribbon if loaded. 

4. Remove the two retaining snap rings and thin washer from the electronics 
side of the TTR supply hub shaft as shown on the next page. Retain the 
washer. Discard the old snap rings. 

5. Pull the TTR supply hub away from the printer and remove the TTR 
supply clutch /encoder assembly. Retain the TTR supply clutch /encoder 
assembly (this assembly is not a spare part), the nylon washer, and the 
thick steel washer. 

6. You can replace the TTR supply hub and TTR supply hub adjusting plate 
now. 



5-20 



Remove and Replace Procedures 




To replace the TTR supply hub and TTR supply hub adjusting plate 

1 . Remove the two Phillips screws securing the TTR supply hub adjusting 
plate to the TTR subplate and install the new adjusting plate in its place. 

2. Install the thick steel washer removed in Step 5 above. Align the TTR clutch 
encoder with the opening in the main deck plate and slide the TTR supply 
hub back through the TTR clutch/encoder, the nylon washer, the motor 
plate, and the TTR subplate. 

Note: Do not remove the motor plate or subplates. Changing the position of these 
plates can alter factory alignment and cause ribbon wrinkling or self-strip 
problems. 



Thick 
Nylon w ^sher 

washer TTR clutch/ j 
encoder 



Thin 
washer 



Snap ring 




3. Install the thin washer removed in Step 4 and the new retaining snap rings. 

4. Reattach the front bezel cover. Ensure that the media access door operates 
properly (snaps firmly shut) after the front bezel cover is installed. 

5. Align the ribbon supply hub as described in "Aligning the TTR Supply 
Hub" in Chapter 3. 

6. Reload media (and ribbon if used) and lower the printhead. 

7. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-21 



3600 Printer Maintenance Manual 



Replacing the Platen Roller and Gear 



The platen roller and platen roller gear can be replaced separately or at the 
same time. To replace the platen roller, the platen roller gear, or both parts, you 
will need some or all of the following parts and tools: 

• Platen roller, Intermec Part No. 061542-003 

• Retaining E-ring, Intermec Part No. 501401 

• Platen roller gear, Intermec Part No. 061557-003 

• Retaining snap ring, Intermec Part No. 501409 

• Roller alignment tool, Intermec Part No. T43150 

• ESD grounding strap 

• #2 Phillips screwdriver 

• Needlenose pliers 

• Snap ring pliers 

To remove the platen roller and platen roller gear 

1 . Switch off the printer power and remove the power cord. 

2. Remove the media cover, the electronics cover, and the front bezel cover 
(refer to "Replacing the Bezel PCB" earlier in this chapter). 

3. Raise the printhead. Remove media and ribbon if loaded. 

4. Remove the retaining snap ring that holds the platen roller gear in place as 
shown on the next page. Retain the washer between the gear and the main 
deck plate. Discard the old snap ring. 

5. Remove the five screws that secure the lower outboard plate to the main 
deck plate and pull the plate away from the rollers. The tear bar and tear 
bar support come loose when the outboard plate is removed. Retain them 
for reassembly. 

Note: Now is a convenient time to replace the liner drive roller and liner drive 
gear/pulley as instructed in the next procedure. 

6. Remove the platen roller and washer. Retain the washer. 

7. The platen roller, the drive gear, or both parts can be replaced now. 



5-22 



Remove and Replace Procedures 




Platen 

roller 

gear 



Tear bar 



Snap 
ring 




Tear bar 
support 



To replace the platen roller and platen roller gear 

1 . Loosen the motor as necessary to mesh the platen roller gear with the 
motor pinion gear and TTR drive gear/pulley upon reassembly. 

2. Install the washer removed in Step 6 and a new retaining E-ring on the 
platen roller and insert it through the main deck plate and into the washer 
removed in Step 4 and the platen drive gear. 

3. Reassemble the tear bar and bar support, and then install the lower 
outboard plate, securing the tear bar assembly and the rollers. 

Note: Use the roller alignment tool during reassembly to align the outboard plate. 

4. Secure the platen drive gear with a new retaining ring and slide the motor 
forward to mesh the motor pinion gear with the platen drive gear and the 
liner drive gear/pulley. Turn the TTR roller drive gear to check for proper 
gear engagement and tighten the motor mounting screws. 

5. Reattach the front bezel cover. Ensure that the media access door operates 
properly (snaps firmly shut) after the front bezel cover is installed. 

6. Reload media (and ribbon if used) and lower the printhead. 

7. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-23 



3600 Printer Maintenance Manual 



Replacing the Liner Drive and Takeup Components 

To replace any combination of the liner takeup hub, liner reverse gears, liner 
drive roller, liner takeup clutch /pulley, liner reverse shaft, liner drive 
gear/pulley, and liner drive belt, you will need some or all of the following 
parts and tools: 

• Liner takeup hub, Intermec Part No. 061562-005 

• Liner drive roller, Intermec Part No. 061568-002 

• Liner reverse gears 1 and 2, Intermec Part No. 061588-002 

• Liner takeup clutch/pulley, Intermec Part No. 061574S-001 (black) 

• Liner reverse shaft, Intermec Part No. 061589-001 

• 2.800ID x .210 drive belt (O-ring), Intermec Part No. 501462-003 

• Liner drive gear/pulley, Intermec Part No. 061569-002 (black) 

• Retaining E-rings, Intermec Part No. 501401 

• Retaining snap rings, Intermec Part No. 501410 

• Roller alignment tool, Intermec Part No. T43150 

• ESD grounding strap 

• #1 and #2 Phillips screwdriver 

• Needlenose pliers 

• Snap ring pliers 

To replace the liner takeup hub and liner reverse gear 1 

1 . Switch off the printer power and remove the power cord. 

2. Remove the media cover, the electronics cover, and the front bezel cover 
(refer to "Replacing the Bezel PCB" earlier in this chapter). 

3. Raise the printhead. Remove media and ribbon if loaded. 

4. Remove the retaining snap rings that hold the liner takeup hub and liner 
reverse gear 1 in place as shown on the next page. Retain the washer 
between the snap rings and the liner takeup subplate. Discard the old snap 
rings. 

5. Pull the liner takeup hub away from the main deck plate to remove it. 
Retain the thick washer between the liner takeup hub and the main deck 
plate. Liner reverse gear 1 can now be removed from behind the liner 
takeup subplate. 

Note: Now is a good time to replace other liner drive and takeup components 
according to the following procedures. 



5-24 



Remove and Replace Procedures 





Liner drive 
gear/pulley 



5-25 



3600 Printer Maintenance Manual 



6. You can replace the liner takeup hub and/or liner reverse gear 1 now. 

7. Install the thick washer removed in Step 5 between the liner takeup hub 
and the main deck plate. Position liner reverse gear 1 between the motor 
plate and the liner takeup subplate and check for proper engagement with 
liner reverse gear 2. 

8. Insert the liner takeup hub through the main deck plate, reverse gear 1, and 
the subplate. Install the washer removed in Step 4 on the hub shaft 
extending through the subplate and secure with two new snap rings. 

9. Reattach the front bezel cover. Ensure that the media access door operates 
properly (snaps firmly shut) after the front bezel cover is installed. 

10. Reload media (and ribbon if used) and lower the printhead. 

11. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 

To replace the liner drive roller 

1. If not already done, switch off the printer power and remove the power 
cord, media cover, electronics cover, and the front bezel cover. Raise the 
printhead and remove the media and ribbon if loaded. 

2. Remove the five screws that secure the lower outboard plate to the main 
deck plate and pull the plate away from the rollers. The tear bar and tear 
bar support come loose when the outboard plate is removed. Retain them 
for reassembly. 



Snap 
ring 



Tear bar 




Tear bar, 
support 



Liner drive Washer 
gear/pulley 



Lower 

outboard 

plate 



Liner drive 
roller 



5-26 




Remove and Replace Procedures 



3. Remove the liner drive gear/pulley retaining E-ring. Retain the washer 
located between the E-ring and the liner drive gear/pulley. Discard the old 
E-ring. 

4. Loosen the motor as necessary to disengage the pinion gear from the liner 
drive gear/pulley to facilitate disassembly. 

5. Remove the liner drive roller, sliding the liner drive gear /pulley off of the 
roller shaft. Retain the washer between the roller and main deck plate. The 
gear/pulley will remain trapped by the drive belt until the belt is removed 
as described in the following procedure. Be sure to retain the washer 
between the gear/pulley and the main deck plate when it comes loose. 

Note: Now is a convenient time to replace other liner drive and takeup components 
according to the following procedures. 

6. You can replace the liner drive roller now. 

7. Install the first washer you removed in Step 5 and a new retaining E-ring 
on the liner drive roller shaft. Position the liner drive gear /pulley and the 
second washer you removed in Step 5 between the motor plate and the 
main deck plate. Then insert the liner drive roller through the main deck 
plate into the washer and gear/pulley. 

Note: The gear/pulley will be under some tension from the drive belt. 

8. Reassemble the tear bar and bar support and install the lower outboard 
plate, securing the tear bar assembly and the rollers. 

Note: Use the roller alignment tool during reassembly for proper alignment of the 
outboard plate. 

9. Secure the liner drive gear/pulley with the washer removed in Step 3 and a 
new retaining E-ring. 

10. Slide the motor forward and mesh the motor pinion gear with the liner 
drive gear/pulley and the platen roller gear. Turn the TTR roller drive gear 
to check for proper gear engagement and tighten the motor mounting 
screws. 

11. Reattach the front bezel cover. Ensure that the media access door operates 
properly (snaps firmly shut) after the front bezel cover is installed. 

12. Reload media (and ribbon if used) and lower the printhead. 

13. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-27 



3600 Printer Maintenance Manual 



To replace liner reverse gear 2, the liner takeup clutch/pulley, liner reverse shaft, 
liner drive gear/pulley, and liner drive belt 

1 . If not already done, perform Steps 1 through 5 of the preceding liner roller 
replacement procedure. 

2. Remove the retaining snap ring that holds the liner reverse shaft, takeup 
clutch/pulley, and reverse gear 2 in place. Retain the washer located 
between the snap ring and subplate. Discard the old snap ring. 




Liner takeup 
clutch/pulley 
assembly 



Liner 

reverse 

shaft 

Snap ring 



Snap ring 




. washer x reverse 
-gear 



5-28 




Remove and Replace Procedures 



3. Remove the liner takeup hub and reverse gear 1 as described in Steps 4 and 
5 of that procedure (page 5-24). 

4. Push the liner reverse shaft through the main deck plate, sliding off the 
takeup clutch/pulley and reverse gear. Separate the drive belt from the 
drive gear/pulley and clutch/pulley. 

5. You can replace the liner drive gear/pulley, liner drive belt, takeup 
clutch/pulley, liner reverse shaft, or reverse gear 2 now. 

To reassemble the liner drive and takeup components 

1 . Install the first washer you removed in Step 5 of the previous liner roller 
replacement procedure and a new retaining E-ring on the liner drive roller 
shaft. Loop the drive belt around the liner drive gear/pulley and position 
the gear /pulley and the second washer you removed in Step 5, between the 
motor plate and the main deck plate. 

2. Insert the liner drive roller through the main deck plate into the washer and 
gear/pulley. Secure the liner drive gear/pulley with a new retaining E-ring. 

3. Reassemble the tear bar and bar support and install the lower outboard 
plate, capturing the tear bar assembly and the rollers. 

Note: Use the roller alignment tool during reassembly for proper alignment of the 
outboard plate. 

4. Fit the drive belt around the liner takeup clutch/pulley. Position the 
clutch/pulley and reverse gear 2 between the subplate and motor plate 
with the clutch/pulley located at the cutout in the motor plate. 

Note: The clutch/pulley will be under some tension from the drive belt. 

5. Insert the D-shaped end of the liner reverse shaft through outboard side of 
the main deck plate, the takeup clutch /pulley, reverse gear 2, and the liner 
takeup subplate. Install the washer removed in Step 2 and a new snap ring. 

6. Install the liner takeup hub and liner reverse gear 1 as described in Steps 7 
and 8 of that procedure. 

7. Slide the motor forward and mesh the motor pinion gear with the liner 
drive gear/pulley and the platen roller gear. Turn the TTR roller drive gear 
to check for proper gear engagement and tighten the motor mounting 
screws. 

8. Reattach the front bezel cover. Ensure that the media access door operates 
properly (snaps firmly shut) after the front bezel cover is installed. 

9. Reload media (and ribbon if used) and lower the printhead. 

10. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-29 



3600 Printer Maintenance Manual 



Replacing the Stepper Motor 



To replace the stepper motor, you will need the following parts and tools: 

• Main stepper motor and cable assembly, Intermec Part No. 061551-002 

• ESD grounding strap 

• #2 Phillips screwdriver 

To replace the stepper motor 

1. Switch off the printer power and remove the power cord, the media cover, 
and the electronics cover. 

2. Unplug the motor cable from the main PCB and remove the motor from the 
motor plate and motor mount bracket. 




Screw 
(3 places) 



Stepper 
motor 



install 
a screw in this 
Motor mounting hole. 

P late 



3. Mount the new motor loosely to the motor plate with the cable positioned 
at the bottom rear corner. Properly mesh the pinion gear with the platen 
drive gear and the liner drive gear before tightening the screws completely. 

4. Plug the motor cable into the main PCB. Check that the motor cable-to- 
main PCB connection is correctly aligned before applying power to avoid 
damaging the main PCB. 

5. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-30 



Remove and Replace Procedures 




Replacing the AC Plug/Input Filter 



To replace the AC plug and input filter assembly, you will need the following 
parts and tools: 

• 3600 line AC plug and filter assembly, Intermec Part No. 060246-001 

• ESD grounding strap 

• #1 and #2 Phillips screwdriver 

• Needlenose pliers 

To replace the AC plug and input filter 

1. Switch off the printer power and remove the power cord, the media cover, 
and the electronics cover. 

2. Disconnect the three push-on connectors attached to the back of the AC 
plug/input filter assembly. 




Push-on 
connectors 



AC power 
plug & filter 



(2 places) 



3. Remove the two screws securing the AC plug/input filter assembly to the 
main deck plate and remove the assembly. 

4. Install the new AC power plug and input filter assembly and secure it with 
the two screws removed in Step 3. 

5. Reconnect the three push-on connectors removed in Step 2. 

6. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-31 



3600 Printer Maintenance Manual 



Replacing the Power Switch/Circuit Breaker 

To replace the power switch and circuit breaker assembly, you will need the 
following parts and tools: 

Note: The 220-volt printer uses a 1 amp power switch/circuit breaker and the 115-volt 
printer uses a 2 amp power switch/circuit breaker. 

• AC power switch /circuit breaker, Intermec Part No. 501273-001 (2A) or 
AC power switch /circuit breaker, Intermec Part No. 501273-002 (1A) 

• ESD grounding strap 

• Needlenose pliers 

• #2 Phillips screwdriver 

To replace the power switch/circuit breaker 

1 . Switch off the printer power and remove the power cord. 

2. Remove the media cover and the electronics cover. 

3. Disconnect the two leads with push-on connectors attached to the power 
switch. 



Rear 
panel ~ 



Tabs ^ 




Power switch/ 
circuit breaker 



Transformer lead 

AC power plug lead 




5-32 



Remove and Replace Procedures 




4. Compress the tabs that hold the power switch secured to the back plate and 
push it out of the main deck plate. 

5. Install the power switch by pushing the new receptacle into the cutout in 
the main deck plate. 

6. Reattach the two push-on connectors removed in Step 3. 

7. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



Replacing the Transformer 



To replace the transformer, you will need the following parts and tools: 
Note: The printer uses a different transformer for 220-volt and 115-volt printers. 

• XFMR, 3600, 47-63HZ, 100V/120V, Intermec Part No. 585525-001 or 
XFMR, 3600, 47-63HZ, 200V/240V, Intermec Part No. 585525-002 

• ESD grounding strap 

• #2 Phillips screwdriver 

To replace the transformer 

1. Switch off the printer power and remove the power cord, the media cover, 
and the electronics cover. 

2. Disconnect the transformer cable from the main PCB and the two leads 
with push-on connectors from the AC power plug and the power switch. 



Transformer 



Screw 
(2 places) 



Power switch/ 
circut breaker 



Main PCB 




5-33 



3600 Printer Maintenance Manual 



3. Remove the two screws holding the transformer to the base plate and slide 
the transformer toward the front of the printer to free it from the metal tabs, 
lifting it away from the printer. 

4. Install the replacement transformer and push it toward the back of the 
printer securing it under the tabs in the printer main deck plate. 

5. Secure the transformer to the printer main deck plate with the two screws 
removed in Step 3. 

6. Reattach the transformer cables to the main PCB, the AC power receptacle, 
and the power switch. 

7. Install the electronics cover, the media cover, and the power cord, and 
check the printer for proper operation. 



5-34 




PCB Drawings and Schematics 



PCB Drawings and Schematics 




This chapter contains the assembly drawings, parts lists, and schematic diagrams for 
the 3600 main PCB. 



PL# 


061591 


-003 




TITLE 


: PCB ASSY, MAIN, 3600 




PAGE 1/10 


PL REV: D 














02231995 




RUN 


DATE: 


Feb 


23 15:1S 


):02 














ITEM QTY/UM 


PART NO. 


REFDES 


DESCRIPTION 




X 


Y F/B 


1 


1 




061590- 


-003 




PCB, MAIN, 3600 










2 


0.001 


RL 


046766 






LBL.STK. .2 3HX1 . 5 0L, 4-HI . 


4MIL. 








3 


3 




584274 




XU6 


SOC.32-POSN. DIP, LOW PROFILE 














1! 




XU8 


















1! 




XU9 












4 


2 




056914 




U12 


IC, ASIC, THERMAL COMPENSATION 


6.5 


3.1 


F 








1! 




U32 






5.1 


3.1 


F 


5 


1 




060691- 


-001 


U25 


CONFIG GAL, 16V8, ASIC INTFC 


6.9 


4.7 


F 


6 


1 




060693- 


-001 


U13 


CONFIG GAL, 16V8, DRAM CONTROL 


5.7 


4.7 


F 


7 


1 




061869- 


-001 


U23 


CONFIG GAL, 22V10, ASIC/OPTINTFC 


6.3 


5.3 


F 


8 


1 




061870- 


-001 


U20 


CONFIG GAL, 16V8, DSACK/FIFOCNTL 


6.4 


4.7 


F 


9 


1 




061871- 


-001 


U21 


CONFIG GAL, 16V8, STEP MOT 


CNTL 


3.5 


0.4 


F 


10 


1 




550694 




R192 


RES.CARB 1.00W 5% 820.0 


OHM 


9.7 


1.3 


F 


11 


1 




550893 




R219 


RES,CARB, 2W, 5%, 750.0 OHM 




7.8 


0.2 


F 


12 


11 




551800 




R160 


RES.S/M, O OHM JUMPER 




1.0 


2.3 


F 














R2 5 






1.0 


1.1 


F 














R2 51 






1.0 


2.6 


F 














R252 






1.6 


1.1 


F 














R2 5 3 






1.3 


1.4 


F 














R2 5 4 






1.0 


2.5 


F 














R2 5 5 






1.0 


1.0 


F 














R2 5 6 






1.3 


1.2 


F 














R2 5 7 






1.0 


0.9 


F 














R2 5 8 






1.3 


1.3 


F 














R259 






1.6 


1.2 


F 


13 


1 




555450 




R125 


RES. POT. SIDE ADJ.W/KNOB 


10KOHM 


0.3 


5.1 


F 


14 


1 




555901 




R6 


RES.S/M. POT TOP ADJ. 100 


KOHM 


8.4 


3.5 


F 


15 


1 




555909- 


-001 


R191 


RES, S/M, POT, TOP ADJ, 20 KOHM 


8.4 


3.1 


F 


16 


2 




556600 

1! 




R214 
R224 


RES, S/M, FILM, .12W,5%,100 


OHM 


4.4 
4.0 


0.7 
0.5 


F 
F 


17 


16 




556603 

II 
II 
II 
II 
II 
II 
II 
II 
II 
II 
II 
II 
II 
II 
II 




Rl 

Rll 

R35 

R36 

R74 

R75 

R107 

R108 

R113 

R142 

R157 

R164 

R185 

R212 

R2 4 

R2 41 


RES . S/M, FILM, . 12W, 5% 4.7 


KOHM 


3.2 
3.2 
5.4 
5.4 
5.8 
6.5 
2.8 
3.2 
3.2 
9.5 
7.1 
6.3 
6.6 
6.7 
1.0 
1.3 


0.6 
0.8 
6.0 
5.8 
4.4 
4.0 
0.3 
1.0 
0.1 
3.0 
4.4 
5.2 
4.4 
3.8 
2.5 
1.4 


F 
F 
F 
F 
F 
F 
F 
F 
F 
F 
F 
F 
F 
F 
F 
F 


18 


81 




556604 

II 




R2 
R3 


RES, S/M, FILM, .12W,5%,10 


KOHM 


5.4 
4.7 


5.9 
6.0 


F 
F 








I 


1 




R5 






1.0 


1.1 


F 



6-3 



3600 Printer Maintenance Manual 



PL# 061591-003 

PL REV: D 

RUN DATE: Feb 23 15:19:02 



TITLE: PCB ASSY, MAIN, 3600 



PAGE 2/10 
02231995 



ITEM QTY/UM PART NO. REFDES 



DESCRIPTION 



F/I 



R8 
R9 
RIO 
R12 
R13 
R14 
R15 
R16 
R17 
R19 
R2 
R2 3 
R2 4 
R2 5 
R2 6 
R2 7 
R2 8 
R2 9 
R32 
R33 
R37 
R38 
R3 9 
R40 
R41 
R42 
R4 3 
R44 
R4 5 
R4 6 
R4 7 
R48 
R4 9 
R50 
R51 
R52 
R53 
R54 
R55 
R56 
R57 
R58 
R5 9 
R60 
R61 
R62 
R63 
R64 
R65 
R66 
R67 
R68 
R69 
R70 



5 


8 


4 


3 


F 


4 


7 


5 


9 


F 


1 


3 


1 


5 


F 


4 





4 


5 


F 


4 





4 


6 


F 


3 


3 


5 


8 


F 


6 


8 


5 





F 


6 


6 


5 





F 


1 


3 


5 


3 


F 


4 


5 


4 





F 


6 


7 


3 


7 


F 


5 


3 


4 





F 


5 


3 


4 


1 


F 


2 


2 


1 


7 


F 


1 


7 


3 


4 


F 


3 


7 


5 


2 


F 


3 


7 


5 


3 


F 


4 





5 


2 


F 


1 





2 


4 


F 


1 


2 


1 


8 


F 


3 


3 


5 


8 


F 


4 





5 


3 


F 





3 


3 





F 





3 


3 


1 


F 





6 


3 





F 





5 


3 





F 





5 


3 


3 


F 





6 


3 


3 


F 





5 


3 


5 


F 





6 


3 


5 


F 





6 


4 


4 


F 





6 


4 


6 


F 





6 


4 


7 


F 





6 


4 


8 


F 





6 


4 


8 


F 





6 


4 


9 


F 





6 


5 


1 


F 





6 


5 


2 


F 


2 


9 


3 


4 


F 


2 


4 


5 


2 


F 


1 


3 


3 





F 


1 


3 


3 


1 


F 


1 


3 


3 


2 


F 


1 


3 


3 


3 


F 


1 


3 


3 


4 


F 


1 


3 


3 


5 


F 


1 


3 


3 


6 


F 


1 


3 


3 


7 


F 


1 


3 


4 


5 


F 


1 


3 


4 


6 


F 


1 


3 


4 


7 


F 


1 


3 


4 


8 


F 


1 


3 


4 


9 


F 


1 


3 


5 





F 



6-4 



PCB Drawings and Schematics 




PL# 061591-003 

PL REV: D 

RUN DATE: Feb 23 15:19:02 



TITLE: PCB ASSY, MAIN, 3600 



PAGE 3/10 
02231995 



ITEM QTY/UM PART NO. 



REFDES 



DESCRIPTION 



F/B 



19 



20 



21 



22 70 



M 


R71 


II 


R72 


II 


R95 


II 


R110 


II 


R118 


II 


R131 


II 


R133 


II 


R134 


II 


R145 


II 


R146 


II 


R153 


II 


R155 


II 


R156 


II 


R158 


II 


R183 


II 


R187 


II 


R193 


II 


R194 


II 


R195 


II 


R201 


II 


R203 


II 


R2 04 


II 


R206 


II 


R222 


556605 


R121 


II 


R2 37 


II 


R239 


556607 


R21 


II 


R96 


II 


R116 


II 


R120 


II 


R141 


II 


R238 


II 


R2 4 7 


556613 


R117 


II 


R218 


II 


R229 


556629 


R7 6 


II 


R77 


II 


R78 


II 


R7 9 


II 


R80 


II 


R81 


II 


R82 


II 


R83 


II 


R84 


II 


R85 


II 


R8 6 


II 


R87 


II 


R88 


II 


R8 9 


II 


R90 


II 


R91 


II 


R92 



RES, S/M, FILM, . 12W, 5%, 47 KOHM 



RES, S/M, FILM, . 12W, 5%, 100 KOHM 



RES, S/M, FILM, . 12W, 5%, 10 OHM 



RES, S/M, FILM, . 12W, 5%, 47 OHM 



1. 


.3 


5. 


.1 


F 


1. 


.3 


5. 


.2 


F 


4. 


.3 


3. 


.3 


F 


4. 


.4 


1. 


.2 


F 


3. 


.7 


1. 


.3 


F 


8. 


.9 


4. 


.3 


F 


9. 


.2 


4. 


.0 


F 


8. 


.5 


4. 


.0 


F 


3. 


.7 


1. 


.0 


F 


3. 


.5 


0. 


.8 


F 


3. 


.2 


0. 


.9 


F 


4. 


.0 


5. 


.8 


F 


7. 


.1 


4. 


.3 


F 


1. 


.2 


2. 


.2 


F 


2. 


.8 


0. 


.7 


F 


10. 


.0 


3. 


.8 


F 


4. 


.7 


4. 


.0 


F 


7. 


.5 


4. 


.1 


F 


10. 


.0 


3. 


.9 


F 


4. 


.0 


5. 


.8 


F 


4. 


.0 


5. 


.6 


F 


4. 


.0 


5. 


.7 


F 


3. 


.3 


5. 


.7 


F 


2. 


.5 


2. 


.8 


F 


3. 


.5 


1. 


.0 


F 


8. 


.9 


3. 


.2 


F 


10. 


.7 


2. 


.0 


F 


4. 


.7 


1. 


.2 


F 


5. 


.0 


1. 


.0 


F 


9. 


.2 


4. 


.2 


F 


5. 


.0 


0. 


.2 


F 


4. 


.7 


0. 


.3 


F 


10. 


.0 


3. 


.5 


F 


10. 


.1 


3. 


.4 


F 


10. 


.5 


2. 


.3 


F 


10. 


.6 


1. 


.9 


F 


10. 


.5 


0. 


.1 


F 


7. 


.5 


6. 


.0 


F 


7. 


.5 


5. 


.8 


F 


7. 


.5 


5. 


.9 


F 


7. 


.5 


5. 


.6 


F 


7. 


.5 


5. 


.7 


F 


1. 


.7 


3. 


.3 


F 


7. 


.5 


5. 


.5 


F 


7. 


.5 


5. 


.4 


F 


1. 


.7 


3. 


.1 


F 


7. 


.5 


5. 


.3 


F 


1. 


.7 


3. 


.0 


F 


7. 


.5 


5. 


.2 


F 


1. 


.7 


3. 


.2 


F 


2. 


.0 


3. 


.2 


F 


2. 


.0 


3. 


.0 


F 


2. 


.0 


2. 


.9 


F 


2. 


.0 


3. 


.1 


F 



6-5 



3600 Printer Maintenance Manual 



PL# 061591-003 

PL REV: D 

RUN DATE: Feb 23 15:19:02 



TITLE: PCB ASSY, MAIN, 3600 



PAGE 4/10 
02231995 



ITEM QTY/UM PART NO. 



REFDES 



DESCRIPTION 



F/I 



23 



556640 



R93 
R94 

R102 
R103 
R109 
Rill 
R112 
R130 
R139 
R140 
R154 
R159 
R161 
R162 
R163 
R165 
R166 
R167 
R168 
R169 
R170 
R171 
R172 
R173 
R174 
R175 
R176 
R177 
R178 
R179 
R180 
R181 
R182 
R184 
R197 
R205 
R209 
R211 
R213 
R215 
R220 
R221 
R227 
R232 
R233 
R2 35 
R236 
R2 4 2 
R2 4 3 
R2 4 4 
R2 4 5 
R246 
R248 
R198 



RES, S/M, FILM, . 12W, 5%, 150 OHM 



2 





1 


6 


F 


3 


7 


5 


4 


F 


5 


9 





9 


F 


5 


9 





1 


F 


5 


9 


1 


1 


F 


5 


9 





3 


F 


9 


7 


3 


8 


F 


3 


2 





2 


F 


4 


5 





2 


F 


5 


9 


1 


5 


F 


3 


2 





7 


F 


2 





1 


7 


F 


7 


5 


6 


1 


F 


6 


3 


5 





F 


7 


5 


4 


7 


F 


7 


5 


4 


8 


F 


7 


5 


4 


6 


F 


7 


5 


5 





F 


7 


5 


4 


9 


F 


2 


2 


1 


6 


F 


2 





1 


9 


F 


2 





1 


8 


F 


7 


5 


3 


7 


F 


7 


5 


3 


5 


F 


7 


5 


3 


3 


F 


7 


5 


3 





F 


7 


5 


3 


1 


F 


7 


5 


3 


2 


F 


7 


5 


2 


9 


F 


7 


5 


4 


5 


F 


7 


5 


4 


4 


F 


7 


5 


4 


3 


F 


7 


5 


4 


2 


F 


7 


8 


3 


9 


F 


6 


1 


4 


7 


F 


7 


5 


3 


8 


F 


7 


5 


2 


8 


F 


7 


5 


3 


4 


F 


7 


5 


3 


6 


F 


5 


9 





7 


F 


5 


9 


1 


3 


F 


5 


9 





5 


F 


5 





1 


1 


F 


5 





1 


2 


F 


5 








3 


F 


5 








4 


F 


4 


7 





5 


F 


5 


5 


5 


6 


F 


3 


2 





4 


F 


3 


5 





1 


F 


3 


2 





3 


F 


3 


2 





5 


F 


2 





1 





F 


6 


2 


3 


8 


F 



6-6 



PCB Drawings and Schematics 




PL# 061591-003 

PL REV: D 

RUN DATE: Feb 23 15:19:02 



TITLE: PCB ASSY, MAIN, 3600 



PAGE 5/10 
02231995 



ITEM QTY/UM PART NO. 



REFDES 



DESCRIPTION 



F/B 



25 


5 


556648 


R34 






II 


R115 






I! 


R123 






I! 


R132 






I! 


R143 


26 


9 


556650 


R105 






II 


R114 






I! 


R128 






I! 


R129 






II 


R147 






II 


R216 






II 


R223 






II 


R226 






II 


R230 


27 


1 


556651 


R189 


28 


10 


556658 


R4 






II 


R98 






II 


R122 






II 


R126 






II 


R127 






II 


R137 






II 


R148 






II 


R150 






II 


R199 






II 


R200 


29 


1 


556665 


R136 


30 


1 


556670 


R186 


31 


2 


556672 


R149 






II 


R228 


32 


3 


556674 


R124 






II 


R217 






II 


R2 34 


33 


1 


556676 


R106 


34 


1 


556687 


R101 


35 


1 


556690 


R138 


36 


1 


556692 


R196 


37 


2 


556710 


R30 






II 


R104 


38 


2 


556721 


R225 






II 


R231 


39 


2 


556742 


R31 






II 


R73 


40 


4 


556837-301 


R119 






II 


R135 






II 


R151 






II 


R152 


41 


2 


556837-161 


R7 






II 


R100 


42 


4 


556838-287 


R18 






II 


R22 






II 


R97 






II 


R99 


43 


4 


561008 


C65 






II 


C124 



RES, S/M, FILM, . 12W, 5%, 390 OHM 



RES, S/M, FILM, . 12W, 5%, 470 OHM 



RES, S/M, FILM, . 12W, 5%, 510 OHM 
RES, S/M, FILM, . 12W, 5%, 1.0 KOHM 



RES, S/M, FILM, . 12W, 5%, 2 . KOHM 

RES, S/M, FILM, . 12W, 5%, 3 . 3 KOHM 

RES, S/M, FILM, . 12W, 5%, 3 . 9 KOHM 

RES, S/M, FILM, . 12W, 5%, 5 . 1 KOHM 



RES, S/M, FILM, . 12W, 5%, 6.2 KOHM 
RES, S/M, FILM, . 12W, 5%, 22 KOHM 
RES, S/M, FILM, . 12W, 5%, 30 KOHM 
RES, S/M, FILM, . 12W, 5%, 36 KOHM 
RES, S/M, FILM, . 12W, 5%, 330 KOHM 

RES, S/M, FILM, . 12W, 5%, 1 .0 MOHM 

RES, S/M, FILM, . 12W, 5%, 9.1 MOHM 

RES, S/M, FILM, 1/8W, 1%, 1 OHM 



RES, S/M, FILM, 1/8W, 1%, 4 . 99KOHMS 
RES, S/M, FILM, 1/4W, 1%, 1 .0 OHMS 

CAP, ALUM, RDL LEAD, 5 0VMIN, 100UF 



3. 


.0 


6. 


.0 


F 


9. 


.2 


4. 


.4 


F 


10. 


.7 


4. 


.3 


F 


9. 


.2 


4. 


.1 


F 


9. 


.2 


3. 


.5 


F 


5. 


.9 


1. 


.0 


F 


5. 


.9 


1. 


.2 


F 


3. 


.5 


1. 


.1 


F 


5. 


.9 


1. 


.6 


F 


5. 


.9 


1. 


.4 


F 


5. 


.9 


0. 


.2 


F 


5. 


.9 


0. 


.4 


F 


5. 


.9 


0. 


.8 


F 


5. 


.9 


0. 


.6 


F 


8. 


.4 


2. 


.9 


F 


1. 


.5 


0. 


.3 


F 


10. 


.4 


3. 


.4 


F 


8. 


.4 


3. 


.3 


F 


0. 


.6 


5. 


.2 


F 


4. 


.0 


0. 


.7 


F 


4. 


.0 


0. 


.6 


F 


10. 


.1 


3. 


.2 


F 


10. 


.7 


3. 


.0 


F 


10. 


.7 


2. 


.3 


F 


10. 


.6 


2. 


.6 


F 


10. 


.7 


3. 


.5 


F 


10. 


.0 


3. 


.6 


F 


10. 


.4 


3. 


.2 


F 


8. 


.9 


4. 


.1 


F 


10. 


.7 


3. 


.4 


F 


4. 


.4 


0. 


.9 


F 


4. 


.0 


0. 


.9 


F 


2. 


.5 


0. 


.7 


F 


2. 


.5 


0. 


.3 


F 


9. 


.5 


2. 


.8 


F 


9. 


.2 


3. 


.3 


F 


5. 


.1 


5. 


.7 


F 


2. 


.8 


0. 


.8 


F 


4. 


.4 


1. 


.0 


F 


4. 


.0 


1. 


.3 


F 


4. 


.9 


5. 


.7 


F 


6. 


.2 


4. 


.0 


F 


6. 


.2 


0. 


.3 


F 


5. 


.0 


1. 


.4 


F 


4. 


.7 


1. 


.1 


F 


4. 


.7 


0. 


.6 


F 


10. 


.6 


1. 


.7 


F 


10. 


.5 


2. 


.5 


F 


7. 


.3 


1. 


.6 


F 


7. 


.3 


1. 


.8 


F 


7. 


.3 


1. 


.7 


F 


7. 


.3 


1. 


.9 


F 


9. 


.7 


2. 


.1 


F 


9. 


.7 


0. 


.6 


F 



6-7 



3600 Printer Maintenance Manual 



PL# 061591-003 

PL REV: D 

RUN DATE: Feb 23 15:19:02 



TITLE: PCB ASSY, MAIN, 3600 



PAGE 6/10 
02231995 



ITEM QTY/UM PART NO. REFDES 



DESCRIPTION 



F/I 



44 
45 
46 

47 



561018-001 

561908 

563602 

I! 

563605 



49 



61 



563 



563 



06 



00 



C125 

C140 

C123 

C53 

C46 

C54 

C55 

C56 

C126 

C127 

C128 

C129 

C141 

C35 

C81 

C82 

CI 

C2 

C3 

C4 

C5 

C6 

C7 

C8 

CIO 

C12 

C13 

C15 

C16 

C17 

C18 

C19 

C20 

C21 

C23 

C25 

C26 

C27 

C28 

C29 

C30 

C31 

C32 

C33 

C34 

C36 

C37 

C38 

C39 

C41 

C42 

C43 

C45 



CAP,AL,ELCTLT,R/L, 63V, 12000UF 
CAP.AL.R/L 16V 4 7 00. UF 
CAP.S/M,TANT, 10V MIN+-20%, 10UF 

CAP.S/M,TANT.35V, 20%, 1UF 



CAP, S/M, TANT, 6VMIN, 10%, 68UF 



CAP, S/M, CER, 50VMIN, 20%, .1 UF 



9 


7 


2 


6 


F 


4 


1 





2 


F 


8 


1 


2 





F 


6 


7 





4 


F 


2 


5 





2 


F 


7 


6 


1 


4 


F 


7 


5 





3 


F 


7 


2 





3 


F 


1 


8 


1 





F 


1 


2 





7 


F 


1 


5 





6 


F 


1 


8 





7 


F 


2 


5 





8 


F 


2 


9 


2 


9 


F 


2 


5 


1 





F 


6 


8 


6 





F 


1 





1 


2 


F 


1 


6 





3 


F 


5 


8 


5 


8 


F 


5 


4 


5 


1 


F 


4 


2 


4 


3 


F 


4 


2 


5 


6 


F 


4 


1 


5 


1 


F 


4 


7 


4 


2 


F 


1 





1 


8 


F 


4 


7 


5 


8 


F 


3 


7 


6 





F 


4 


7 


5 


7 


F 





9 


2 


9 


F 


2 





5 


2 


F 





9 


4 


6 


F 


2 


2 


1 


9 


F 


2 


4 


3 


3 


F 


3 


2 


3 


3 


F 


1 


5 


1 


5 


F 


7 


1 


3 


2 


F 


5 


9 


3 


1 


F 


6 


3 


4 


3 


F 


6 


8 


4 


3 


F 


3 


7 


2 


1 


F 


6 


5 


3 


8 


F 


5 


6 


4 


3 


F 


6 


5 


2 


4 


F 


4 





2 


8 


F 


4 


4 


1 


1 


F 


5 








5 


F 


6 


4 


5 


9 


F 


3 


6 


2 


8 


F 


3 


7 





8 


F 


4 


4 





8 


F 


8 


9 


4 


2 


F 


5 


3 





8 


F 


10 


5 


2 





F 



6-8 



PCB Drawings and Schematics 




PL# 061591-003 

PL REV: D 

RUN DATE: Feb 23 15:19:02 



TITLE: PCB ASSY, MAIN, 3600 



PAGE 7/10 
02231995 



ITEM QTY/UM PART NO. 



REFDES 



DESCRIPTION 



F/B 







M 


C48 






II 


C50 






II 


C51 






II 


C58 






II 


C60 






II 


C61 






II 


C62 






II 


C64 






II 


C67 






II 


C70 






II 


C72 






II 


C75 






II 


C76 






II 


C107 






II 


C108 






II 


C109 






II 


C110 






II 


cm 






II 


C112 






II 


C113 






II 


C117 






II 


C136 






II 


C137 






II 


C138 


50 


4 


563701 


C9 






II 


Cll 






II 


C22 






II 


C24 


51 


15 


563702 


C40 






II 


C68 






II 


C96 






II 


C99 






II 


C100 






II 


C101 






II 


C102 






II 


C103 






II 


C104 






II 


C105 






II 


C106 






II 


C131 






II 


C132 






II 


C133 






II 


C134 


52 


7 


563705 


C14 






II 


C52 






II 


C57 






II 


C59 






II 


C66 






II 


C73 






II 


C74 


53 


2 


563715 


C44 






II 


C49 


54 


23 


563720 


C77 



CAP, S/M,CER, 50WVDC, 5%, 10 PF 



CAP, S/M,CER, 50WVDC, 5%, 100 PF 



CAP, S/M,CER, 50VMIN, 10%, .01 UF 



CAP, S/M,CER, 50VMIN, 20%, .22 UF 
CAP, S/M,CER, 50VMIN, 5%, 150 PF 



5. 


.0 


1. 


.3 


F 


5. 


.5 


0. 


.8 


F 


4. 


.7 


1. 


.0 


F 


4. 


.9 


5. 


.7 


F 


4. 


.4 


1. 


.3 


F 


8. 


.9 


4. 


.4 


F 


5. 


.4 


0. 


.1 


F 


9. 


.8 


2. 


.8 


F 


10. 


.7 


3. 


.3 


F 


10. 


.7 


3. 


.2 


F 


10. 


.5 


2. 


.9 


F 


10. 


.7 


3. 


.7 


F 


3. 


.2 


2. 


.1 


F 


3. 


.5 


0. 


.9 


F 


3. 


.7 


0. 


.9 


F 


4. 


.0 


0. 


.8 


F 


5. 


.2 


2. 


.4 


F 


5. 


.7 


3. 


.1 


F 


5. 


.1 


3. 


.8 


F 


4. 


.5 


3. 


.1 


F 


2. 


.8 


1. 


.9 


F 


8. 


.7 


4. 


.0 


F 


5. 


.3 


4. 


.3 


F 


4. 


.9 


4. 


.2 


F 


5. 


.1 


5. 


.8 


F 


4. 


.9 


5. 


.8 


F 


6. 


.1 


4. 


.0 


F 


6. 


.1 


3. 


.8 


F 


10. 


.7 


2. 


.5 


F 


10. 


.4 


3. 


.3 


F 


10. 


.0 


3. 


.7 


F 


4. 


.3 


3. 


.4 


F 


7. 


.8 


3. 


.0 


F 


7. 


.8 


3. 


.3 


F 


7. 


.8 


3. 


.5 


F 


7. 


.8 


3. 


.7 


F 


7. 


.8 


3. 


.1 


F 


7. 


.8 


3. 


.2 


F 


7. 


.8 


2. 


.9 


F 


7. 


.8 


3. 


.8 


F 


7. 


.8 


3. 


.6 


F 


7. 


.8 


3. 


.4 


F 


7. 


.8 


2. 


.8 


F 


4. 


.7 


5. 


.6 


F 


9. 


.2 


4. 


.3 


F 


0. 


.6 


5. 


.3 


F 


10. 


.4 


4. 


.0 


F 


9. 


.5 


3. 


.0 


F 


9. 


.4 


3. 


.3 


F 


9. 


.4 


4. 


.1 


F 


2. 


.2 


0. 


.3 


F 


2. 


.5 


0. 


.6 


F 


5. 


.3 


4. 


.8 


F 



6-9 



3600 Printer Maintenance Manual 



PL# 061591-003 

PL REV: D 

RUN DATE: Feb 23 15:19:02 



TITLE: PCB ASSY, MAIN, 3600 



PAGE 8/10 
02231995 



ITEM QTY/UM PART NO. REFDES 



DESCRIPTION 



F/I 







M 


C78 






II 


C79 






II 


C80 






I! 


C83 






I! 


C84 






II 


C85 






I! 


C86 






I! 


C87 






I! 


C88 






I! 


C89 






II 


C90 






I! 


C91 






I! 


C92 






I! 


C93 






I! 


C94 






II 


C114 






I! 


C116 






I! 


C130 






I! 


C135 






I! 


C139 






II 


C143 






I! 


C144 


55 


4 


563729 


C47 






11 


C95 






I! 


C97 






II 


C98 


56 


2 


563731 


C63 






1! 


C142 


57 


4 


563736-001 


C115 






M 


C118 






II 


C120 






I! 


C121 


58 


27 


564202 


D3 






II 


D5 






II 


D7 






II 


D8 






II 


D18 






II 


D19 






II 


D21 






II 


D22 






II 


D23 






II 


D24 






II 


D25 






II 


D29 






II 


D30 






II 


D31 






II 


D32 






II 


D34 






II 


D35 






II 


D36 






II 


D37 






II 


D38 






II 


D40 



CAP, S/M,CER, 50VMIN, 10%, 1 UF 

CAP, S/M,CERM, . 001UF, 200V, X7R 
CAP, S/M, CER, 0603, 25V, . 01UF 

DIODE, S/M, TYPE BAS16 



4. 


.1 


4. 


.8 


F 


5. 


.3 


5. 


.4 


F 


4. 


.5 


4. 


.2 


F 


2. 


.4 


3. 


.4 


F 


3. 


.2 


3. 


.4 


F 


2. 


.0 


5. 


.3 


F 


5. 


.8 


5. 


.7 


F 


6. 


.3 


4. 


.4 


F 


6. 


.8 


4. 


.4 


F 


5. 


.6 


4. 


.4 


F 


4. 


.0 


2. 


.9 


F 


6. 


.4 


5. 


.8 


F 


3. 


.5 


2. 


.9 


F 


6. 


.5 


2. 


.5 


F 


6. 


.5 


3. 


.7 


F 


5. 


.2 


2. 


.5 


F 


5. 


.1 


3. 


.7 


F 


1. 


.0 


0. 


.7 


F 


3. 


.7 


0. 


.7 


F 


2. 


.8 


1. 


.8 


F 


4. 


.9 


5. 


.6 


F 


5. 


.7 


5. 


.2 


F 


9. 


.3 


0. 


.3 


F 


9. 


.2 


2. 


.6 


F 


10, 


.5 


0. 


.3 


F 


9. 


.3 


1. 


.1 


F 


10. 


.6 


1. 


.8 


F 


1. 


.4 


0. 


.3 


F 


1. 


.5 


0. 


.5 


F 


1. 


.9 


1. 


.0 


F 


1. 


.1 


0. 


.7 


F 


1. 


.9 


0. 


.8 


F 


3. 


.3 


6. 


.0 


F 


3. 


.2 


5. 


.5 


F 


9. 


.0 


0. 


.6 


F 


9. 


.0 


0. 


.9 


F 


10. 


.7 


1. 


.7 


F 


10. 


.7 


1. 


.5 


F 


10. 


.5 


2. 


.2 


F 


4. 


.8 


1. 


.4 


F 


10. 


.7 


1. 


.3 


F 


4. 


.8 


0. 


.9 


F 


4. 


.7 


0. 


.2 


F 


10. 


.5 


1. 


.2 


F 


5. 


.8 


0. 


.2 


F 


4. 


.2 


0. 


.6 


F 


4. 


.4 


0. 


.6 


F 


5. 


.8 


1. 


.2 


F 


5. 


.8 


0. 


.4 


F 


5. 


.8 


1. 


.5 


F 


5. 


.8 


0. 


.8 


F 


5. 


.8 


1. 


.3 


F 


5. 


.8 


0. 


.6 


F 



6-10 



PCB Drawings and Schematics 




PL# 061591-003 

PL REV: D 

RUN DATE: Feb 23 15:19:02 



TITLE: PCB ASSY, MAIN, 3600 



PAGE 9/10 
02231995 



ITEM QTY/UM PART NO. 



REFDES 



DESCRIPTION 



F/B 







M 


D42 






II 


D43 






I! 


D44 






I! 


D45 






II 


D46 






1! 


D47 


59 


4 


564206 


Dl 






M 


D2 






II 


D4 






II 


D14 


60 


1 


564217 


D28 


61 


3 


564219 


D15 






II 


D16 






II 


D20 


62 


1 


564235 


D9 


63 


2 


564238 


D26 






II 


D27 


64 


4 


564239-002 


D6 






II 


D10 






II 


D12 






II 


D13 


65 


1 


565091-001 


Q5 


66 


4 


565101 


Q2 






II 


Q9 






II 


Q10 






II 


Q16 


67 


1 


565102 


Q17 


6 8 


1 


565110 


Q7 


69 


1 


565127-001 


Q15 


70 


8 


565130-001 


Ql 
Q3 

Q4 
Q6 
Qll 
Q12 
Q13 
Q14 


71 


1 


567024 


VR1 


74 


1 


578020 


U28 


75 


1 


578023 


U5 


76 


4 


578081 


U7 






II 


U10 






II 


U14 






II 


U15 


77 


1 


578087 


U4 


78 


2 


578131 


Ull 






II 


U24 


79 


1 


578132 


U30 


80 


1 


578134 


Ul 


81 


1 


578135 


U2 9 


82 


1 


578137 


Dll 


83 


1 


578145 


Y2 


84 


2 


578209-001 


U16 



DIODE, S/M, TYPE MMBD301 



DIODE, S/M TYPE 5231 ZENER, 5V 
DIODE, S/M TYPE 5245 ZENER, 15V 



DIODE, S/M, TYPE 522 6, ZENER, 3 . 3V 
DIODE, S/M, TYPE BAS21,200VBR 

DIODE, S/M, DUAL, 6A, 100V 



XSTR,FET, 60V, 30A 

TRANS, S/M, NPN, TYPE 4401 



TRANS, S/M, TYPE 4403, PNP 
XSTR, S/M, TYPE 6427 DARLINGTON 
XSTR, S/M,T5551,NPN, 160V 
XSTR, S/M, HEXFET, 60V, 7 . 7A 



VOLTAGE REGULATOR, 5V, 1A 
IC, S/M, TYPE 74HC04 
IC, S/M, TYPE 74HC32 
IC, S/M, TYPE 74HCT245 



IC, S/M, TYPE 14C89,CMOS RCVR 

IC, S/M, TYPE IDT72105,FIFO 

IC, S/M, TYPE MC145041 

IC, S/M, TYPE 75ALS180 

IC, S/M, TYPE MC34064 

IC, S/M, TYPE LM385-1.2 
CRYSTAL, S/M, 24MHZ 

IC, S/M, TYPE 74ALS257 



4 


8 





8 


F 


5 


8 


1 





F 


5 


3 





1 


F 


4 


6 


1 


4 


F 


4 


6 





9 


F 


4 


6 





8 


F 


1 


9 





6 


F 


1 


8 





6 


F 


3 


5 


6 





F 


1 


1 


2 


8 


F 


10 


5 


3 





F 


10 


7 


1 


2 


F 


9 








2 


F 


10 


5 


1 


5 


F 


2 


5 





4 


F 


9 








8 


F 


9 








4 


F 


7 


8 





6 


F 


9 


3 





7 


F 


8 


7 





6 


F 


8 


3 





6 


F 


9 


8 





2 


F 


3 


4 


5 


5 


F 


10 


3 


3 


8 


F 


10 


3 


4 





F 


3 


2 


1 


2 


F 


10 


6 


2 


7 


F 


10 


5 


1 


3 


F 


10 


7 


2 


2 


F 


6 


9 





9 


F 


6 


3 





9 


F 


6 


9 


1 


6 


F 


6 


3 


1 


6 


F 


6 


3 


1 


3 


F 


6 


9 


1 


3 


F 


6 


3 


2 





F 


6 


9 


2 





F 


7 


5 





2 


F 


5 


8 


5 


4 


F 


3 


6 


5 


7 


F 





9 


3 


2 


F 





9 


4 


9 


F 


3 


3 


2 


4 


F 


3 


8 


2 


4 


F 


1 





2 





F 


2 


1 


2 


3 


F 


2 


7 


2 


3 


F 


8 


6 


4 


3 


F 


1 





1 


5 


F 


1 


8 





3 


F 


2 


2 





5 


F 


5 


8 


3 


9 


F 


3 


6 


3 


2 


F 



6-11 



3600 Printer Maintenance Manual 



PL# 061591-003 

PL REV: D 

RUN DATE: Feb 23 15:19:02 



TITLE: PCB ASSY, MAIN, 3600 



PAGE 10/10 
02231995 



ITEM QTY/UM PART NO. REFDES 



DESCRIPTION 



F/I 







M 




U18 


85 


1 


578211- 


-001 


U3 


86 


3 


578245- 

II 
II 


-001 


U2 

U27 
U31 


87 


1 


578294- 


-001 


U2 6 


88 


1 


578300- 


-001 


U22 


89 


2 


578301- 

II 


-001 


U17 
U19 


90 2. 


.610 


580231 






91 


1 


580285 




J10 


93 


3 


580359 

II 
II 




Jll 
J12 
J13 


94 


1 


580434 




Jl 


95 


1 


581976 




J14 


96 


2 


581978 

II 




J9 
J15 


97 


2 


582065 

II 




SW1 
SW2 


98 


1 


582282- 


-012 


J2 


99 


1 


585636- 


-001 


LI 


100 


1 


586298 




BT1 


101 


1 


586548- 


-001 


Q8 


102 


1 


588000 




Yl 


103 


2 


580213 







IC,S/M,TYPE MC68332,MICPRCS 
IC, S/M,LM2 93,DUAL VOLT COMPTR 



IC, S/M,DRAM, 256KX16, SOJ 

IC, S/M, 234,RS-232 DRVR 

IC, S/M,HIP4081,HF DRVR, 80V 

CONN, 2 6-POSN . HDR . SNGL . ROW/ .10 
CONN, 8-POSN, HDR, . 156, FRICTION 
CONN. HDR. 4-POSN. STRAIGHT THRO. 



CONN.25-POSN.D/SUB W/SNAP 
CONN, 4 0-POSN,HDR, .1 DBL ROW 
CONN, 6-POSN, HDR, .100, FRIC LOCK 

SW, 8-POSN. DIP, SIDE ACTUATED 

CONN, S/M, PIN, . 8MMX6MM, 80-POSN 

INDUCTOR, 10 UH 

HLDR. BATTERY, AA SIZE 

SENSOR, S/M, REFLECTIVE 

CRYSTAL, S/M 32.768 KHZ 

CONN. 2-POSN. SHORTING, .10 CTRS . 



4. 


.0 


3. 


.2 


F 


4. 


.7 


4. 


.9 


F 


4. 


.0 


1. 


.1 


F 


10. 


.4 


3. 


.6 


F 


2. 


.8 


0. 


.5 


F 


1. 


.5 


2. 


.2 


F 


1. 


.5 


0. 


.9 


F 


5. 


.4 


1. 


.2 


F 


5. 


.4 


0. 


.5 


F 


8. 


.8 


1. 


.0 


F 


10. 


.6 


4. 


.2 


F 


9. 


.7 


4. 


.3 


F 


9. 


.7 


3. 


.5 


F 


0. 


.7 


1. 


.2 


F 


10. 


.2 


1. 


.0 


F 


7. 


.3 


0. 


.6 


F 


8. 


.9 


3. 


.3 


F 


0. 


.1 


3. 


.9 


F 


0. 


.1 


4. 


.8 


F 


5. 


.5 


2. 


.1 


F 


9. 


.1 


1. 


.7 


F 


1. 


.9 


5. 


.8 


F 


9. 


.4 


4. 


.6 


F 


5. 


.0 


6, 


.0 


F 



6-12 



H H H H 
5 4 3 2 



REVISION 
SHEET 



REV STAFUS 
OF SHEETS 





REVISK 


ONS 




K_V 


CLCCRIPTIDN 


DATE 


U'n'Ai'/N & AITXOVlL 


D 


-OS 3 RELEASED AT REV D 






E 


-004 PER ECN 023890 






F 


-C05 PER ECN 024053 






H 


-COS MFG RELEASE 


4-27-95 


NEDION TOfrNSELL 




NOTES: UNLESS OTHERWISE SPECIFIED 

1 . CAUTION: THIS ASSEMBLY CONTAINS MOS DEVICE (S) WHICH 

MAY BE DAMAGED BY STATIC DISCHARGE. USE SPECIAL HANDLING 
PER PROCEDURE 60SO13. 



CAUTION 
SUBJECT TO DAMAGE BY 
STATIC ELECTRICITY 



[T^MARK PART NUMBER LABEL, ITEM 2 WITH 061591 AND DASH NUMBER 
TO WHICH MANUFACTURED PER PROCESS SPECIFICATION 047233. 

CHANGES REQUIRE SAC APPROVAL 



PLACE ITEM 90 CONNECTOR PINS AT THE FOLLOWING LOCATIONS 
J3,JB,J7,US,TP14 1 TP15 1 TP16. 




SEE SEPARATE PARTS LIST FOR 061591-006 



■006 



NOTICE 

THIS DRAWING SHALL NOT BE DUPLICATED OR USED FDR ANY PURPOSE 
OTHER THAN THAT FOR WHICH PROVIDED. THE INRORMATION DISCLOSED 
HEREIN ORIGINATED BY AND IS THE PROPERTY OF INTERMEC CORPORATION 
AND EXCEPT FOR RIGHTS EXPRESSLY GRANTED BY WRITTEN CONSENT, SUCH 
NFORNATION SHALL NOT BE DISCLOSED OR DISSEMINATED WHOLE OR IN PART 
INTERMEC CORPORATION RE5ERVES ALL PATENT, PROPRIETARY, DESIGN, USE, 
SALE, MANUFACTURING AND REPROOUCTION RIGHTS THERETO. 



CAD DB.REF-061591-006h.uy1 
SYSTEM - VALID 7 ALLEGRO 8.0 



UNLESS OTHERWISE 
SPECIFIED, 
DIMENSIONS ARE 
IN INCHES 

.XX ± 

.XXX ± 

ANCLES ± — 



APPROVALS DATE 



DRAW r PETERSON 11-03-94 



ntermec 



SDOl 3E-TH AVENUE WEST 
EVEREFT, WA 915203-9230 



CHECKED 
RESP ENG 



T ' T PCB ASSY, MAIN 
MEMORY EXPANSION, 3400 



.SIZE CAGE CODE DRAWING NUMBER 

. D 00825 061591 



Rrv 

H 



CCA L ■>!' AND NODI) 



SHEET 1 OF b 



006 MFG R r FASF 



DRAWN & APPROVED 



!- 07 95 vnio'i ~nw-l5 r ll 




A 



r 0R RE r ERENCE ONLY 



CAD DoOEF 001 59 I U00hcy2.bc 

.-, - ,-. ,-,.,- - r 6001 36TH AVFKLF « r S~ 

Q-- ' ' ' •■■''- -V-K-l , SA 9300 i %'K 

SIZL CAGL aOil •'ASH 10 NUMBER RLV 

D ooB'-'o 061591 



SCALE 2/1 



SHEE~ 2 



A 



3600M.073 





'-~- N-SH 


Ri'G 


LZK 

3^ 


1K 1 


A _ 

f.:\) 









REUIBJONB 




REV 


DESCRIPTION 


DATE 


DRRHN & APPROVED 


D 


-003 RELER5ED RT REU D 






E 


-004 MEG RELEASE 















cuir:n_vjD:c 

CU[[LH1_BLl- 
RFfFT 



5 

P flLEOl 








JIF1 

d 
1 




PAUSE /EMPTY 
















SWITCH ^ 












R19G 


5 





3600M.075 




Replacement Parts 



Replacement Parts 




This chapter contains a list of 3600 printer replacement parts referenced to 
illustrations. 



Replacement Parts 



The following table is a copy of the 3600 service parts matrix with illustration 
references added. It lists the 3600 printer parts that can be ordered for 
replacement by the part number indicated. Each part on the list has an ID 
number corresponding to a callout on the illustration showing its location. 
Multiple ID numbers occur when parts are used more than once or when 
another view of the part is called out for clarification. A list of documentation 
part numbers you can order is also provided. 

To order replacement parts, contact Intermec: 

Intermec Corporation 
6001 36th Avenue West 
P.O. Box 4280 
Everett, WA 98203-9280 

Note: Only the listed printer parts are spares available for purchase. 



3600 Printer Spare Parts List 



ID No. 


Part Number 


Description 


01,07 


061564-001 


BEZEL, TOP COVER 


02,99 


061550-007 


PLATE, MAIN DECK 


03, 05, 06, 08, 


522690 


SCREW, THD ROLL W/CONE 


42, 43, 45, 70, 






83,86,119,146 






04 


059101-009 


COVER, ELECTRONICS 


09 


521528-001 


TAPE, TRANSFER, ADH, .010 T 


10 


059710-001 


MAGNET, DOOR LATCH 


11 


059013-002 


LENS, MEDIA INSPECTION 


12 


060622-001 


LBL, INTL LOADING INSTRUC 


13 


061547S-006 


COVER, REAR 


14,34 


061544-004 


PLATE, BASE 


15 


061545S-002 


COVER, MEDIA ACCESS 


16,46 


061546S-004 


BEZEL, FRONT COVER 



7-3 



3600 Printer Maintenance Manual 



ID No. 


Part Number 


Description 


17,27 


059012-009 


PLATE, FRONT COVER 


18, 20, 21, 40, 


526036 


SCREW, PHP, W/INT STAR 6-32 X .375 


66, 155 






19,54 


059052S-001 


PCB ASSY, BEZEL 


22 


059387-003 


BRACKET, HINGE 


23 


060315-002 


ROLLER, PINCH 


24 


061581-001 


SHAFT, PINCH ROLLER 


25 


501445 


RING.RTN. .125 DIA. E-RING, ZINC 


26,44 


061579S-003 


DOOR ASSY, MEDIA ACCESS 


28,95 


061555-001 


EXTRUSION, PRINTED SPAN 


29, 116 


521118-001 


WASHER, SPRING, CONL .175 X .50 


30 


505613 


SCREW, SOC HD CAP 8-32 


31,56 


061548-001 


CABLE ASSY, RIBBON PRINTHEAD 


32,73 


059032-002 


BRACKET, PRINTHEAD PIVOT 


33,76 


061559-003 


BLOCK, PIVOT 


35 


501272-001 


FEET, RUBBER, ADHESIVE BACKED 


36 


061570-003 


HEATSINK ASSY, PRINTHEAD 


37 


505767 


SCREW, PHM, 8-32X .375 


38 


061611S-001 


PRINTHEAD, 6.6 INCH, 5 MIL, 3600 


39 


062862-002 


CAP, BIAS SCREW 


41,87 


061556-004 


PLATE, LOWER MODULE, OUTBD 


47 


059103-002 


BUTTON, CAP 


48 


058776-004 


LIGHT PIPE, DOCK/CHARG 


49 


061591S-005/061591E-005* 


PCB ASSY, MAIN (^exchange part no.) 


50,55 


059727-001 


CABLE ASSEMBLY, BEZEL 


51,98 


059496-004 


CABLE ASSY., LABEL TAKEN SENSOR 


52 


061578-001 


CABLE ASSY, LBL MARK SENSOR 


53, 123 


059495-001 


CABLE ASSY, LABEL GAP 


57 


586142 


INS. SHIM 


58 


507846 


SPACER, .235 RD. NY. SHOULDER 


59 


505312 


SCREW, PHM, PHIL 4-40X.25 


60 


061549-003 


HEATSINK, PCB DRIVERS 



7-4 



Replacement Parts 




ID No. 


Part Number 


Description 


61 


585525-001 


XFMR, 3600, 47-63HZ, 100V/120V 




585525-002 


XFMR, 3600, 47-63HZ, 200V/ 240V 


62 


041776 


JUMPER AY, .25 TERM. LUGS, 4-IN 


63 


060246-001 


FILTER ASSY, LINE AC 


64 


506103 


WASHER, LOCK, EXT. STAR, NO. 


65 


501273-001 


CIRCUIT BREAKER, SWITCH, 2 AMP 


65 


501273-002 


CIRCUIT BREAKER, SWITCH, 1 AMP 


67 


506111 


WASH. LOCK. SPLIT, NO. 4 


68 


060544-001 


GASKET, ESD, RS232 CONNECT 


69 


507659-001 


SCREW, JACK, 4-40X .312 


71 


586229 


BATTERY, LITHIUM 3.6V, 1.75AH 


72, 145 


525034-001 


SCREW, THD ROLL W/CONE, 8- 


74, 93, 106, 


506013 


WASHER, SST, .255ID X .407OD 


108, 132 






75 


506827-001 


SPRING, COMP. 360 OD .44F 


77 


059122-001 


LEVER, PRINTHEAD ADJUSTMENT 


78 


507717 


FASTENER, COTTER PIN 25 


79 


061561-001 


SPRING, TORSION, PRINTHEAD RETURN 


80 


061560-001 


SHAFT, TTR RIBBON 


81, 100, 136 


501409 


RETAINING RING .250 DIA BASIC 


82 


059039-011 


HANDLE, PRINTHEAD PRESSURE 


84 


063225-001 


PLATE, UPPER MODULE, OUTBD 


85 


061576S-002 


CAM ASSEMBLY, HEAD PRESSURE 


88 


061568-002 


ROLLER, LINER DRIVE 


89 


061542-003 


ROLLER, PLATEN 


90 


061543-002 


ROLLER, DRIVE 


91 


061558-002 


BAR, STRIP SUPPORT 


92, 109, 134 


501401 


RTN RING .250 DIA 8610/2 


94 


061541-001 


BAR, TEAR 


96, 131 


501394-001 


MOUNT, WIRE ROUTING, ADH B 


97 


059423-002 


MOUNT, MARK SENSOR 



7-5 



3600 Printer Maintenance Manual 



ID No. 


Part Number 


Description 


101 


061902-001 


ARM, MEDIA BRAKE 


102 


062352-002 


BELT, FLAT POLYURETHANE, 1.75 ID 


103 


061900-003 


DRUM, MEDIA BRAKE 


104 


062746-002 


BUSHING, MEDIA ARM 


105 


506022 


WASHER, NYLON, .257ID X .5 


107 


061587-005 


PLATE, INBOARD MEDIA SUPPLY 


110 


061903-001 


POST, MEDIA SUPPLY 


111 


061586-003 


ROLLER, MEDIA SUPPLY 


112 


059718-002 


RING, LABEL SUPPLY 


113 


061904-002 


CAP, MEDIA SUPPLY 


114 


061552-003 


BRACKET, MEDIA PATH, UPPER 


115 


059030-005 


EDGEGUIDE, OUTER 


117 


059781-001 


THUMBSCREW, ASSEMBLY 


118 


061553-003 


BRACKET, MEDIA PATH, LOWER 


120 


061567-002 


SPRING, TORSION, PAPER PATH 


121 


059509-002 


SHAFT, PAPER PATH 


122 


062396-001 


MOUNT, LBL GAP SENSOR 


124 


061901-001 


PEDAL, MEDIA BRAKE 


125, 127, 165 


061562-005 


HUB ASSY 


128 


061566-003 


BRACKET, CORE LOCKING 


129, 142, 150 


506040-005 


WASHER, FLAT SST .327 X .50 X .30 


130 


060214-001 


FLAP, PRINTHEAD CBL RESTR 


133 


061563-002 


GEAR/PULLEY, CLUSTER, L/H 


135 


061557-003 


GEAR, PLATEN, D SHAFT 


137 


061569-002 


GEAR/PULLEY CLUSTER, RH 


138 


506040-004 


WASHER, FLAT SST, .817 X 1.0 


139 


062927S-001 


CLUTCH, ASSY, RIBBON TRANSPORT TAKE-UP, 3600 
SPARE 


140 


506049-001 


WASHER, FLAT, NYLON .320ID 


141, 160 


501461-001 


RETAINING RING EXTERNAL .395 


143, 152 


501410 


RETAINING RING .310 DIA, GRIPPING 



7-6 



Replacement Parts 




ID No. 


Part Number 


Description 


144 


061551-002 


CABLE ASSY, MOTOR MAIN STEPPER 


147 


059102-002 


BRACKET, MOTOR MOUNT 


148 


061554-004 


PLATE, MOTOR 


149 


061584-002 


SUBPLATE, LINER TAKEUP 


151, 154 


505359-001 


SCREW, W/CONE WASH, 8-32X1 


153 


061588-002 


GEAR, LINER REVERSE 


156 


062603-001 


PLATE, HUB ADJUST 


157 


061583-002 


SUBPLATE, TTR 


158 


061574S-001 


CLUTCH, ASSY, SELF STRIP LINER TAKE-UP, 3600 SPARE 


159 


506040-007 


WASHER, FLAT SST 446 X .56 


161 


061589-001 


SHAFT, LINER REVERSE 


162, 163 


501462-003 


O-RING, 2.800ID X .210THK 


164 


506040-006 


WASHER, FLAT SST .327 X .500 X .080 


166 


061565-002 


CLAMP, LINER HUB 


not shown 


061605-001 


CORE, RIBBON, 3600, CDBD, 6.7 IN. 


not shown 


062197S-003 


FIRMWARE, 3600, VER 1.1, SPARE 



3600 Manuals 



Part No. 


Description 


062732-001 
062733-001 


3600 Bar Code Label Printer User's Manual 
3600 Bar Code Label Printer Getting Started Guide 



7-7 




3600M.092 




Appendix 



Appendix 




This appendix describes the theory of operation for the 3600 printer. 

Functional Description of the 3600 Mechanics 

This section describes the basic mechanical functionality of the 3600 printer. 

The 3600 printer has a sheet metal frame (base plate and main deck plate) to 
which mechanical and electrical components are attached. The printer holds, 
moves, routes for contact by the printhead, and stores label stock and ribbon by 
electronically controlled mechanical means. Sheet metal covers protect media 
and components. 

The printer has one electrically powered motor that is the source of 
simultaneous movement for all of the driven parts. The motor shaft uses a 
pinion gear to impart drive force to the rotating parts, producing ribbon and 
liner movement. 

The motor pinion gear drives the platen roller by meshing with the 96-tooth 
gear mounted on the end of the roller. The platen roller gear contacts a 96-tooth 
gear /pulley assembly on the TTR drive roller, assisting ribbon movement and 
providing drive to the TTR takeup hub by means of the drive belt (O-ring) 
between the TTR drive gear/pulley and the TTR takeup clutch/pulley. 

The motor pinion gear also meshes with a 96-tooth gear/pulley on the liner 
drive roller, assisting liner movement and providing drive to the liner takeup 
hub by means of another drive belt between the liner drive gear/pulley and the 
liner takeup clutch/pulley. 

The liner takeup clutch/pulley rotates an idler shaft and gear that meshes with 
an identical gear on the liner takeup hub shaft to produce reverse rotation of 
the liner takeup hub. 

The TTR drive function and the liner drive function each use one-way clutches 
to facilitate label retract. A one-way clutch is part of each roller drive gear. The 
TTR drive roller gear is white, while the liner drive roller gear is black. This 
makes it easy to distinguish between the two gears, which is necessary because 
the clutches are one-way in opposite directions and would not work if 
interchanged. 

The clutch /pulley assemblies on the TTR takeup hub and liner reverse shaft 
are similarly color coded because they have different torque values. The 
springs inside are color coded as well: TTR = white gear, white pulley/clutch, 
white spring (inside); liner = black gear, black pulley/ clutch, black spring. 

The belt driven TTR takeup (16 in-oz) hub and liner reverse (34 in-oz) idler 
shaft use one-way clutches that manage takeup force and prevent slackening 
during retract. Reversed liner takeup rotation produces less slippage. 

The TTR supply hub uses an 18 in-oz slip clutch. The hub has a TTR encoder 
sense label attached to it that is used for ribbon motion sensing. 



A-3 



3600 Printer Maintenance Manual 



A media supply assist roller and brake assembly are part of the media supply 
post function. The free spinning roller reduces the drag of the media core over 
the stationary supply post, allowing the media to turn smoothly during 
printing. When printing stops, the media slackens under the upper media 
guide, causing the media brake pedal and brake arm to lower onto the rubber 
contact strip on the brake drum, which inhibits media roll momentum by 
stopping the assist roller. 

Functional Description of the 3600 Electronics 

This section describes the basic electronic functionality of the 3600 printer. 
Components are identified by the reference designators used on the schematic 
diagrams (provided in Chapter 6). 

Power Supply 

The power supply for the 3600 is primarily a linear supply with a switching 
buck converter for the 24V printhead supply. The switching buck converter 
takes the unregulated +50V and uses a switching transistor to reduce the 
output voltage to +24V. The base mechanism is equipped with an AC input 
filter and a transformer that supplies the board 12 VAC and 50 VAC. 

+5V 

The +5V supply is generated from the 12 VAC inputs on connector J10. Diode 
bridge D12 rectifies the AC voltage and regulator VR1 regulates the DC voltage 
to +5V. Capacitors C53 through C56 are used for filtering and storing energy 
for hold time at power down or blackout. VR1 is rated at 1.5 A and is 
sufficiently heatsinked to handle this amount of current. The typical +5V load 
is approximately 1A. 

+40V 

The +40V supply is generated from the 40 VAC inputs on connector J10. Diode 
bridge D13 rectifies the AC voltage capacitors C95 and C58 that are used as 
filters. 40 VAC is unregulated and used for the stepper motor voltage. The 
+40V supply is also zenered down to 5.1V to supply the motor logic. This 
prevents excessive motor currents on power up. Another zener diode is used to 
supply 15V that is used by the +24V buck converter. 

+24V 

The +24V supply is generated by a switching buck converter. 



A-4 



Appendix 




Power Fail Detection 

The power fail detection circuitry consists of IC U31, diodes D7, D8, D9, and 
Dll and various resistors and capacitors. Diodes D7 and D8 rectify the 
incoming 12 VAC, and R101 and R107 act as a divider. D9 is a zener diode used 
to prevent the input on U31 from exceeding +5V. Dll is a 1.235V reference. 
When the voltage at pin 3 of U31 exceeds 1.235V, the output is pulled up by a 
10K resistor, R183. R104 adds some hysterisis to help filter out noise or 
brownouts. C44 and C49 are also for filtering. C46 and R107 set up a time 
constant of 1 .5 60 Hz cycles to filter out brownouts. The hold time of the +5V 
varies with line voltage and the state of the printer. The printer exceeds 20 ms 
at low line and when not printing. 

Battery 

The battery is used to back up the static RAM for font, format, and UDC 
storage. R34 limits the reverse current into the battery, a safety requirement for 
lithium batteries. The battery itself is a 3.6V lithium battery with 1.75 Ah. Diode 
D4 is a low leakage schottky diode used to isolate the battery voltage from 
VCC of the circuit card when the power is off, but it has minimal voltage drop 
to RAMVCC when power is on. Transistor Q2 and IC U5 cause the RAM chip 
select to be held in a high (inactive) state when /RESET is low to prevent 
inadvertent writes to RAM during power up or power down. 

Battery Life Calculations 

Battery capacity = 1.75 Ah 

RAM Data Retention current = 20 |iA maximum, 1 |iA typical 

With printer off all the time and worse case scenario: 

Battery life = 1.75 Ah / 20 |iA = 87,500 hours = 10 years 

With printer off all the time and typical case: 

Battery life = 1.75 Ah / 1 jjA = 1,750,000 hours = 200 years 

Reset 

/RESET is generated by MKC34064 under voltage sensing circuit, U29. The 
output of U29 is low for any supply voltage less than 4.6V. 



A-5 



3600 Printer Maintenance Manual 



Motor Driver 

The motor driver circuit of the 3600 consists of ICs U2, U21, U17, and U19; 
discreet parts Q16, Ql, Q3, Q4, Q6, Qll, Q12, Q13, Q14; and associated diodes, 
resistors, and capacitors. The eight D-MOS FETs make up a dual full-bridge 
motor driver. There are four FETs to drive each motor phase. There are two 
FETs at each end of each motor phase. 

When a phase is driven or turned on, one FET on each end of a phase is turned 
on. One of the FETs will be a high side FET putting 50 volts on one end of the 
winding. The other FET will be a low side FET putting zero volts on that end of 
the winding. 

When the motor is running the windings are being excited first with 50 volts on 
one end, and then the 50 volts on the other end. At no time are both FETs on 
the same end of a winding on at the same time. 

When a winding is turned on, the current is first monitored and then controlled 
by turning the FETs on and off at a high rate. This is called pulse width 
modulation. The current in the winding is monitored measuring the voltage 
across the sense resistors R18, R22, R97, and R99. These voltages are called 
sense_Al and sense_Bl. These voltages are inputs to U2. U2 is a comparator 
that compares a reference voltage (voltage at U2 pins 2 and 6) to the voltages 
sense_Al and sense_Bl. When these voltages become greater than the sense 
voltage the associated out put of U2 switches from low to high. This voltage is 
fed into the GAL U21 and then to the appropriate driver IC U17 or U19 which 
turns the associate FET off. The off time during this pulse width modulation 
cycle is constant and controlled by the C109, R127 for sense_Al or C42, R137 
for sense_Bl. 

The reference voltage on pins 2 and 6 of U2 is established by the pulse width 
modulation input M5. This is an input from the microprocessor to Q15 through 
R108. The duty cycle of this signal controls the reference voltage input to U2. 
The magnitude of this voltage establishes the magnitude of the current in 
motor windings. 

Other inputs from the microprocessor to the GAL U21 circuit are Ml, M2, M3, 
and M4. These inputs control the stepping of the motor. They go into the GAL 
where they are decoded and fed into the driver ICs U17, U19 which turn the 
FETs on and off. 

Reset is the last input to the motor driver circuit. U19 pin 3 is high when reset 
is applied to the DISABLE input of U17. This action ensures that all the FETs 
are held in the off condition to control start up and shut down transients. 



A-6 



Appendix 




Processor 

The processor used in the 3600 is a MMC68332 32-bit integrated 
microcontroller. Based on the MC68020, the MC68332 contains four peripheral 
modules: CPU32, a 32-bit central processing unit; TPU, a complex, 
programmable time processor unit; QSM, a queued serial module; and SIM, a 
system integration module. The MC68332 was chosen for its 32-bit processing 
power along with its high level of integration. 

Chip Selects 

The SIM of the MC68332 allows up to 12 chip selects to be programmed by the 
software for use in the system. We use seven of these chip selects. /CSBOOT is 
used to access the EPROM of the system. It can handle up to 1M of EPROM 
organized as 512K x 16. /CSO and CS1 are used for accessing DRAM, which is 
configured as 512K x 16. /CS2 is used to access the static RAM, which is used 
for font, format, and UDC storage. /CS3 is used to access the ASIC and I/O 
option port. U23 then decodes these chip selects using address lines. /CS4 is 
used for interrupt acknowledge. /CS5 combines the chip selects for both 
loading the FIFO with image data and also for reading the DIP switches. U20 
decodes these chip selects using address lines A16 and A17. /CS6 is used as 
A19. /CS7, /CS8, and /CS9 are reserved to be used as A20, A21, and A22 for 
possible memory expansion. 

TPU 

The TPU is the time processor unit of the MC68332. It has 16 programmable 
channels that can be used to generate output waveforms or capture input 
signals. All of the 16 channels are used in the 3600 printer design. The TPU 
contains built-in functions, but it is also possible to override these functions by 
downloading new functions into the MC68332 standby RAM. The 3600 design 
uses custom TPU functions to perform the following tasks: 

Channel This input captures the /STPINT signal. When /STPINT goes 
active, channel interrupts the CPU to indicate a step, links to channels 1 
through 6 and 10, and sets up a match for the half-step time. 

Channels 1 to 4 These outputs control motor signals Ml to M4 respectively. 
After initialization to set up motor direction, each channel outputs the next bit 
of a programmable bit pattern whenever a link is received from channel 0. A 
fixed delay is set for each channel to ensure that all four channels switch 
simultaneously. 

Channel 5 This output generates the duration portion of the strobe waveform. 
A pulse is generated after a link from channel 0. You can program the pulse 
delay and width. 

Channel 6 This output generates the chopped portion of the strobe waveform. 
A continuous square wave is generated and synchronized with each link from 
channel 0. The square wave frequency and duty cycle are programmable. 



A-7 



3600 Printer Maintenance Manual 



Channels 7 and 8 These outputs control the front panel LEDs. They can be set 
to high, low, or square wave outputs. The square wave output frequency is 
programmable. 

Channel 9 This output is reserved. It has RXD as an input for autodetection of 
the serial communications parameters. 

Channel 10 This is an input for the ribbon sensor. The channel detects 
transitions on the input. If it does not receive a transition before it receives a 
programmable number of links from channel 0, it interrupts the CPU to 
indicate a ribbon failure. 

Channel 11 This output generates the refresh requests for the DRAM. It 
generates a low pulse at a programmable frequency and duration. 

Channel 12 This is an input for the front panel switch. It detects transitions on 
the input, debounces the switch, and interrupts the CPU. 

Channel 13 This output generates a square wave of a programmable 
frequency. It is used to set the current level for the motor driver circuit. 

Channel 14 and 15 These channels are reserved to support a cutter or a wand 
port. 

QSM 

The QSM consists of two modules, a serial peripheral interface (SPI) and serial 
communications interface (SCI). The SPI is used to communicate with the A/D 
converter. It takes continuous readings and stores the values in RAM for 
immediate access by the CPU. The SCI is used for RS-232/RS-485 
communications. Other pins are used as general purpose I/O. 

Interrupt Priority Levels 

The SIM module has seven IRQ pins to help facilitate external interrupts in the 
3600: 

• /I/ORCV, /I/OXMT, /PFAIL, and HF are available as interrupts. 

• /I/ORCV and /I/OXMT are used for communications with the I/O option 
interface. 

• HF is used to indicate that the FIFO needs service. 

• /PFAIL indicates a loss of power. 

• The IRQ pins are used for general purpose I/O. 

Crystal 

The clock synthesizer of the MC68332 can operate from an on-chip, phase- 
locked loop using an external crystal. A 32.768KHz crystal provides a reference, 
allowing the processor to run at frequencies from 131KHz to 16.777MHz. The 
clock synthesizer is programmed to run at 16MHz in the 3600. 



A-8 



Appendix 




Memory 

The MC68332 has separate address busses and data busses. All I/O is memory 
mapped and the SIM chip selects are used to select program space, data space, 
and I/O. 

Static RAM 

The 3600 comes with 128K of battery backed static RAM. The RAM is 
configured as 128Kx8. The chip select for accessing SRAM should be 
configured to at least one wait state. The RAM can also be upgraded to 
512K x 8 by swapping the component at location U6. The jumper between pins 

1 and 2 of J3 must be removed and placed across pins 2 and 3. 

RAM Access Time 

Processor access time >= RAM access time 

3 x CLK >= Tcslow + Tramaccess + Tsetup + Thc32 
3 x 1/16 MHz >= 30 ns + 120 ns + 5 ns + 18 ns 
187.5 ns >=173 ns 

EPROM 

The EPROM for the 3600 consists of two 512K x 8 EPROMs configured as 512K 
x 16, giving a total of 1M of EPROM space. The EPROMs have an access time 
of 150 ns and do not require wait states. 

EPROM Access Time 

Processor access time >= EPROM access time 

2 x CLK >= Tcslow + Tepromaccess + Tsetup 
2 x 1/16 MHz >= 30 ns + 70 ns +5 ns 

125 ns >= 105 ns 

DRAM 

The main memory consists of 256K of dynamic RAM. The DRAM is configured 
as 256K x 16, IC U26. To support the DRAM interface, GAL U13 is used to 
handle refresh and control lines between the DRAM and the processor. See 
Part II, Appendix A for GAL listings of the current configuration. Multiplexors 
U16, U18, and U20 are used to generate the row and column addresses for the 
DRAM. 



A-9 



3600 Printer Maintenance Manual 



Communications Interface 

The communications interface for the 3600 follows the Intermec Standard Data 
Connector standard. Jl is a 25 pin D-sub connector that supports both RS-232 
and RS-485 interfaces. Ul is the RS-485 driver /receiver and U22 and U4 are the 
RS-232 driver and receivers. To further enhance the interface to support 
DTR/RTS flow control, the DTR pin is driven with the PIN 14 signal. This 
arrangement allows the use of standard cables for hardware flow control, 
which enables the user to use commands such as the DOS COPY command 
from any PC. Zero ohm resistors have been incorporated into the RS-232 driver 
outputs so that the previous configuration or other configurations are possible. 

A/D Converter 

The Motorola MC145041 A/D converter is an 11-channel, 8-bit, serial A/D 
converter. The reference is set to +5V. Seven of the eleven channels are used: 

Channel Function 

Label gap sensor 

1 Darkness adjust 

2 Printhead thermistor 

3 Label mark sensor 

4 +40V 

5 Printhead voltage, +24V 

6 Label taken sensor 

The A/D converter is continuously communicating with the MC68332 through 
the SPI. It receives conversion commands and channel addresses while sending 
back results from the previous command. The clock rate for the MC145041 is 
1MHz. 



DIP Switches 

The 3600 has 16 DIP switches to provide configuration and test and service 
operation. 

ASIC and I/O Option Interface 

The 3600 uses an Intermec designed thermal compensation ASIC. This ASIC 
handles the loading of the printhead to implement the dot-by-dot thermal 
management scheme. 

Address/Data Multiplexor 

Since both the ASIC and the I/O option interfaces are designed to interface 
with a processor that has multiplexed address and data, it is necessary to 
multiplex the address and data from the MC68332. ICs U14 and U15 are used 
to route address or data to the AD (0:7) bus. 



A-10 




Appendix 



Chip Select Generation 

GALs U23 and U25 are designed to take the MC68332 bus control signals and 
convert them into ASIC and I/O option control signals. A state machine 
governs the timing of the signals and also dictates that the /OPTION_ASICCS 
from the processor be programmed for two wait states. 

I/O Option Connector 

The I/O option connector J8 is a 40-position pin field. Two chip selects, 
/OPTION* and /BOKI/O*, are used to select either the board identification 
number or the data port. XMT and RCV are outputs from the I/O option cards 
that are inverted and go to the processor to generate communications 
interrupts. 

JlFO 

The FIFOs Ull and U24 are the same part as used in the Intermec 3400 and 
4400 printers. The IDT 72105 is a 256 x 16 FIFO with parallel inputs and serial 
output. The processor loads image data into the FIFO with word writes. At the 
beginning of a line, the MC68332 loads three lines of data into the FIFO. This 
causes the HF flag to go high. The ASIC then begins clocking data out of the 
FIFO. The processor checks each line of the HF flag and loads the next line of 
data if there is still more image to load. If the image has been completely 
loaded, the FIFO empties and the /EF flag goes low. The low /EF flag tells the 
ASIC to stop clocking data from the FIFO. 

Front Panel Interface 

Connector J15 connects to the front panel board. Inputs consist of one button 
(Feed/Pause) and three LEDs (Power, Alert, and Empty/Pause). The Alert 
LED indicates system errors or printhead over-temperature. The Empty/Pause 
LED indicates a paused state or a media fault. 

Debug Interface 

J5 provides a debug interface to the processor, which allows for 
troubleshooting of the main PCB. This interface can be used to put the 
processor into background mode and then send commands to read or write 
memory or register locations. This interface is used for in-house functional 
testing and is used for engineering development. 



A-11 



3600 Printer Maintenance Manual 



Timing 



Row 


Name 


Formula 


Min 


Max 


Margin 


Comment 


ID 


Tclsa 


[3,30] 


3 


30 




332 Clk low to sel asserted 


2V 


Tco 


[2,10] 


2 


10 




GAL Clk to output delay 


3D 


Tchav 


[2,39] 


2 


39 




332 Clk hi to add valid 


4D 


Tsy 


[Tsy 


4 


12 






5C 


Trah 


[15,] 


15 




<13.25> 


DRAM row add hold time 


6C 


Taist 


[5,] 


5 




<38.50> 


332 DSACK setup time 


7D 


Tclsn 


[3,30] 


3 


30 




332 Clk low to sel negated 


8D 


Tsy 


Tsy 


4 


12 






9V 


Tpd 


[3,15] 


3 


15 




GAL Tpd 


IOC 


Tasc 


[0,] 







<6.25> 


DRAM col add setup 


11C 


Tasr 


[0,] 







<65.75> 


DRAM row add setup 


12C 


Tras 


[80,] 


80 




<38> 


DRAM ras low time 


13C 


Tds 


[25,] 


25 




<18.50> 


DRAM 


14V 


Tsy 


[4,12] 


4 


12 




Sel to output HC257 


15D 


Tpd 


Tpd 


3 


15 






16D 


Tpd 


Tpd 


3 


15 






17D 


Tco 


Tco 


2 


10 






18D 


Tpd 


Tpd 


3 


15 






19D 


Tco 


Tco 


2 


10 






20D 


Tpd 


Tpd 


3 


15 






21C 


Teas 


[20,] 


20 




<35.50> 




22D 


Tclsa 


[3,30] 


3 


30 




Same as 1 


23C 


Trp 


[60,] 


60 




<52> 




24C 


Tcah 


[20,] 


20 




<70.75> 




25D 


Tco 


Tco 


2 


10 






26D 


Tpd 


Tpd 


3 


15 






27D 


Tco 


Tco 


2 


10 






28D 


Tchav 


[2,39] 


2 


39 






29C 


Tasr 


[0,] 







<65.75> 




30D 


Tco 


Tco 


2 


10 






31C 


Trpc 


[10,] 


10 




<39.50> 




32D 


Tco 


Tco 


2 


10 






33D 


Tco 


Tco 


2 


10 






34D 


Tclsn 


[3,30] 


3 


30 






35D 


Tclsa 


[3,30] 


3 


30 






36D 


Tco 


Tco 


2 


10 






37C 


Trp 


[60,] 


60 




<57> 





A-12 



Ons 



100ns 



200ns 



300ns 



400ns 



500ns 



600ns 




addsel 
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§ add K 



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3 

3 



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to 




3600 Printer Maintenance Manual 



Functional Description of the 3600 Software 

This section describes the basic software functionality of the 3600 printer. 

Band Buffering and Font Caching 

Image band buffering and font caching allow Intermec printers to image and 
print labels at the same time. Virtually any label length can be accommodated 
due to the circular system of using image memory. After an image band has 
printed, it is reused to image the next part of the label, which means the printer 
can print labels using less memory. 

Image Band Buffering 

Printer throughput is affected by the number of image bands and the print 
speed. If imaging is fast enough, throughput will be maximized by using the 
least number of image bands with the fastest speed (assuming the fastest speed 
delivers the desired print quality). 

Some printers use a fixed size, contiguous portion of RAM for imaging. In 
these cases, a label is imaged in its entirety before printing commences. During 
printing, there is no contention with imaging, so the print speed can remain 
constant. However, if the label is fairly complex, the delay before printing 
becomes very noticeable. In addition, printing of the label must finish before a 
second label is imaged. The combination of these delays impede total printer 
throughput. Another drawback is that the maximum length of a label is limited 
by the size of the RAM. 

With the use of image band buffers (1 band = 1 inch), labels are divided up and 
imaged band by band. Printing begins after the selected number of image 
bands is imaged, minimizing the delay before printing. Imaging of a second 
label can begin while a first is still printing. In addition, the length of a label is 
virtually unlimited. 

With image band buffering, time becomes a critical resource since printing and 
imaging take place simultaneously. Sometimes, a label cannot be imaged fast 
enough to keep up with the print speed. The 3600 printer maintains a constant 
print speed regardless of label complexity. 

Label throughput can be fine-tuned by selecting the number of image bands 
and print speed for a specific label format. Selecting image bands determines 
how much of a label is preimaged before printing starts. 

Selecting too many image bands can lead to print delay. If too few image bands 
are selected, imaging falls behind the print speed. If imaging falls behind 
printing, the printer stops printing the label, sets the speed to 2 ips, sets the 
number of image bands to the maximum, and then reprints the label. This 
condition is known as an image rate error or an image overrun error. 



A-14 



Appendix 




The ideal setting keeps imaging just ahead of printing. This ideal setting can be 
found by the proper selection of image bands and print speed for the label 
format being printed. 

Image Band Example 

The following example shows a format print using image bands. The label is 5 
inches long and is divided into five image bands. The printer is configured for 
three image bands, which means that three bands will be imaged before 
printing begins. 

The dashed lines represent the divisions between the five image bands and the 
arrow (T) represents the portion of the image band that is being printed at that 
time. 




The first diagram shows the first 1 inch of the label imaged into the first image 
band. The other two image bands are still empty. Printing has not begun. 



E£E 



E 



The second 1 inch of label is imaged into the second image band. Printing has 
still not begun. 



A-15 



3600 Printer Maintenance Manual 




Ij&SIBIIKF! 



The third 1 inch of the label is imaged into the third image band. Printing 
begins from the first image band, as indicated by the arrow. At this point, all 
three available image bands have been filled. The first band will be reused after 
it has been completely printed. 




When the first image band is emptied (printed), the fourth band is imaged into 
it. Printing continues from the second image band. As before, this band must 
be emptied before the final band can be imaged into it. 




A-16 



Appendix 




The final 1 inch of the label is imaged into the second image band. Printing 
continues from the third band. At this point, the label has been completely 
imaged but printing has not finished. 




After the third image band is emptied, printing continues from the first image 
band. 




Imaging of a second label could begin in the third image band while the first 
label is still printing. The second label could begin printing immediately after 
the first with no delay, which suggests that the only print delay encountered 
would be during the time when the first bands of the first label were imaged. 

As labels become more complex, the influence that print speed and the number 
of buffers has on throughput is limited by imaging speed. New considerations 
come in to play, such as delay between printing and perceived printer 
performance. Unfortunately, there is no formula to use to calculate an ideal 
configuration. Instead, it will have to be found through trial and error by the 
user. 



A-17 



3600 Printer Maintenance Manual 



Font Caching 

Most of the imaging time during text creation is spent converting character 
description data into character images. The remainder of the time is used to 
copy the character images into image RAM. Font caching helps to eliminate the 
reimaging of characters that have already been used. 

With font caching, a character is imaged into the cache the first time it is 
requested. It is then copied from the cache into the appropriate area of image 
RAM. The next time that same character is needed, it only has to be copied 
from the font cache. The illustration on the following page shows the process of 
generating and caching a specified character. 

When used with band buffering, even if there are no repeated characters in a 
label, font caching may still enhance imaging. If a character is large or is 
positioned near a band boundary, portions of its image may fall into multiple 
bands. The character's image will be referenced repeatedly as each of the bands 
is imaged. As before, if the character is cached, it will only need to be imaged a 
single time. 

Print Energy Compensation 

The digital thermal compensation system and the global compensation system 
combine to provide the printer with maximum printhead energy control to 
optimize print quality. 

Digital Thermal Compensation 

Each dot on the printhead has its own history RAM. This RAM contains a dot's 
previous burn history, what the current burn will be, and what adjacent dots 
are doing. This data, along with the media sensitivity information, is used to 
determine the proper amount of energy for that dot. 

For example, if the dot history showed that the dot had been turned on most of 
the time, this profile would indicate that the energy built up in the dot area was 
sufficient enough for the task and the dot would be turned off for a period of 
time. Using this method provides for a specific amount of energy for the task 
that dot is performing. 

Global Compensation 

Global compensation is the energy management to the printhead that affects all 
of the dots on the printhead. External inputs to this system are the darkness 
adjust control and the online darkness command. Other inputs include the 
ambient temperature, the printhead resistance, and printhead temperature. 



A-18 



Appendix 




Font Caching Flow Chart 



Request for 
character 



Character already 
exists in cache 



Check cache for 
requested character 



Character does 
not exist in cache 



Available memory 
is returned 



Allocate memory 

in cache 

for character 



No memory 
is available 



Image character 
in allocated cache 



Image character 
in reserve cache 



Return 
requested 
character 



A-19